maintenance program

CABIN INTERIORS / DIVISION

-

C&D Zodiac ADC Maintenance Program

C&D Zodiac ACD has implemented a program consisting of five (5) disparate functions to accomplish the goals of our Maintenance Program.

Planned Maintenance (Proactive)1. Predictive Maintenance2. Preventive Maintenance3. Improvement Maintenance4. Corrective maintenance

Unplanned Maintenance (Reactive)1. Emergency / Breakdown maintenance

These functions assist in the identification and reduction of production impacting equipment, system and facility failures. Each of these functions utilizes a system for collecting, recording and analyzing data with the goal of reducing production down time.


Predictive MaintenancePredictive maintenance can be broken down into two major

categories. Statistics-based predictive maintenance analyses data

gathered during proactive and reactive maintenance activities to aide in the determination of patterns of failure. This allows CDZ to Adjust PM Cycles and focus on areas that will minimize or eliminate future failures

Condition-based predictive maintenance, evaluates the condition of equipment by performing periodic or continuous equipment condition monitoring. The ultimate goal is to perform maintenance at a scheduled point in time when the maintenance activity is most cost-effective and before the equipment loses performance within a given threshold.

-


Preventive Maintenance

CDZ is currently implementing a corporate level plan to increase the operator’s ownership and responsibility for a portion of a given machine's maintenance. This program is currently in use on CNC equipment and Paint booths and will be expanded as data is gathered and the program adjusts based on that data. Operators are assigned responsibility for daily visual inspections of critical fluids as well as machine condition and operation, routine maintenance such as filter changes and lubrication, cleaning and the reporting of any issues outside of their identified responsibilities. The PM Forms are kept in a folder attached to the machine and updated by both the Operators and the maintenance staff.

-


Corporate Preventive Maintenance Form

-


Preventive Maintenance(Continued)

1. In Conjunction with the corporate program CDZ ADC utilizes a software package called MaintainIt to generate and store PM work orders. All Capital equipment is assigned a designation in the MaintainIt database and appropriate intervals are set up for tickets to be generated. This can be weekly, bi-weekly, monthly, quarterly, etc. based on the current utilization of the equipment. Initially this is determined by the manufacturer’s recommendations but as the equipment ages or hours of operation are modified, the cycles are altered to adjust for these changes. Each work order includes a checklist of items to be cleaned, serviced or replaced as well as space to record materials used and man hours needed to complete the defined tasks. All records are kept in both hard copy and in the MaintainIt database and can be reviewed as needed. If Issues beyond the scope of the PM work order are identified, the technician files a request through the Unplanned / Breakdown Maintenance system and the work is scheduled based on criticality and production requirements.

-


MaintainIt Daily PM Work Order

-


Improvement Maintenance

The information that is collected and analyzed is also used to determine ways in which future maintenance issues can be minimized or eliminated. This can include alterations or improvements to support equipment, location and floor space requirements, purchase of equipment that requires little or no maintenance, among a host of other possible ways that these issues can be avoided in the future. The Problem

-


Corrective Maintenance

Information from Preventive, Predictive and Unplanned / Breakdown Maintenance programs is collected, analyzed and subsequently used to identify areas of operation, equipment or systems that require further attention to improve on performance or reduce failure rate and thus reduce production impact. This can include modifications to facility systems, Alterations to PM cycles or attention to particular areas of a piece of equipment. The data can also be used to identify process issues in operations, production and maintenance as well as affecting future equipment purchases and identifying previously unidentified critical spares.

-


Unplanned / Breakdown Maintenance

C&D Zodiac ACD currently utilizes a SharePoint database created specifically for processing equipment and facility repairs, modifications, installations, relocations and fabrication requirements. Each request is processed through a series of checks and balances to determine the criticality of the issue and to schedule the required personnel and arrange for the needed equipment time to complete the work. This database is equipped with a knowledge base designed to record any critical information that might be required in a future repair as well as any documentation or vender information on the equipment.

-


Maintenance Request Form

-


Maintenance Request as it appears on the SharePoint Site


SharePoint Support Ticket Report


Unplanned / Breakdown Maintenance(Continued)

Part and material requisition tracking and current status as well as estimated and actual man-hours, equipment downtime and numerous other details are recorded in order to aid in communications with the production and management personnel affected by the work as well as for analysis and subsequent improvement of the maintenance process and identification of potential problems with equipment throughout the plant.

-


SharePoint Support Ticket

-


Corrective Maintenance

Information from the Operations, Preventative and Unplanned / Breakdown Maintenance programs is collected, analyzed and subsequently used to identify areas of operation, equipment or systems that require further attention to improve on performance or reduce failure rate and thus reduce production impact. This can include modifications to facility systems, Alterations to PM cycles or attention to particular areas of a piece of equipment. It can also be used to identify process issues in operations, production and maintenance as well as affecting future equipment purchases and identifying previously unidentified critical spares.

-


Critical Spares

Critical Spares: C&D Zodiac ACD Equipment and Facilities Maintenance Teams work continuously to identify and maintain a stock of critical spare parts, materials and supplies in anticipation of a production critical repair. Baseline critical spares are identified at the time of purchase for any new equipment coming into the facility. Established equipment critical spares are determined by analysis of data gathered over time through the use of the TPM process. This data is reviewed on an ongoing basis and spares are purchased based on both, frequency of failure, impact to production, cost, and availability, shipping cost and delay as well as many other criteria.

-

maintenance program

Documents