Comments on: Can maintenance and operations coexist? A radical process change story

By: Robert Schindler

Robert Schindler — Thu, 09 Jul 2009 15:14:19 +0000

Technically oriented people are few and far between these days so using them primarily as operators may not be the best way to utilize their talents. I have seen some real successes though where we team operators with their maintenance partners to assist in the repairs and over hauls. As they gain experience assisting the mechanics and electricians, they qualify for more and more complicated tasks on their process equipment. But, you have to also meet them half-way with the proper information, some basic training, and the right tools. Ownership drives greater efficiencies so they must be directly involved in all phases of equipment management from selection to PM development and beyond.

By: Inshan Rasool

Inshan Rasool — Wed, 10 Jun 2009 14:01:16 +0000

While I understand what Manish is saying my concern is with what skill level does the Operator come with that would allow him to grow into the person that can perform the “highly technical jobs & overhauling”. While I agree that one would find a few that have this capability I thing that it is few and far between. It would be definitely easier to start up with a Technician who becomes an Operator. The down side to this is finding Technicians who are willing to operate.

By: Manish Paruthi

Manish Paruthi — Fri, 05 Jun 2009 07:24:21 +0000

In today’s manufacturing world Operator Asset Care (OAC) concept is picking up. Many industries, companies are taking initiatives to create OAC culture wherein plant equipment operators take out the production while maintaining their equipments to good health.
In my 12 years of Projects, maintenance engineering career I’ve found that the persons having technical capabilities can give maximum production at low maintenance cost from a machine.
OAC concepts can reduce big maintenance task force, making a lean manufacturing plant team. Maintenance engineer’s (essential part of an organization) skills can be sharpened & utilized to improve plant reliability & cost. An operator also feels involved & doesn’t have monotony in day to day job.
But introducing OAC concept is a herculean task. It involves lot of systematic approach, effort & time. In general, OAC approach shall start from grass root level i.e. cleaning & inspection of a machine where an operator gets opportunity to identify any change in machine condition. There after it shall move to next step i.e. lubrication & minor maintenance or problem fixing. Till than operator shall assist maintenance engineers in performing highly technical jobs & overhauling. Once operator fully develops necessary equipment maintenance skills, can self perform in process quality inspections & eliminate bothering IPQA inspectors, making a manufacturing plant more lean in terms of manpower. One can have ‘Jidoka’ in a manufacturing set up to ensure quality of productivity further.
Behavioral shift from traditional manufacturing set up to next generation manufacturing set up may involve lot of motivation, practical demonstrations (piloting) and trainings. Also time span for this can extend to three or five years.
Once OAC culture is built, manufacturing will become less expensive, more responsive to customer needs.
… Manish Paruthi (mparuthi@its.jnj.com/ manishparuthi@yahoo.com)