how to solve this problem (machine downtime)?

Six Sigma – iSixSigma Forums Old Forums General how to solve this problem (machine downtime)?

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    There are several kind of machines (10 units, almost one-year old) in our factory. We always follow each machines manual for maintenance. The point is there are many problems for these machines, and make our process stop. From the data we collected, those problems mostly different, such as maybe wrong high tem. alarm, next is another malfunction. We investigated and found no wrong operation from operator. And also disucssed with some machine manufacturing technician, they also have not root cause(they are internationl famous brand), Now senior management let BB to deal with it. Does anybody has same issues or can give any suggestion how to do first step? thanks



    Further to previous comments about analysis of defects you should consider ‘variation’ as a cause.
    For example, a wrong temp. alarm in a furnace might be due to a load size and the time it takes for the furnace to achieve a particular set point.
    Originally, SS was all about identifying and reducing sources of variation, but there has been a tendency by those with limited process engineering background to advocate SS only in terms of defects, which is a huge mistake.



    Without knowing much about yoru process, I would propose these general steps:

    Do your own root cause analysis and Pareto your causes of downtime to determine where the pain is.
    Improve those items that cause the most problems.
    Look into SMED for reducing maintenance downtime/start-up.
    Implement a preventive maintenance program for each of the 10 machines based on their functional use/utilization/time between breakdown/etc.  Basically, anticipate the problems that cannot be resolved and fix them before having the breakdown.


    Andejrad Ich

    “3.4 defects per million opportunities” — as I recall, that language is pretty prevalent in really…let me think…yes…ALL six sigma literature.  In fact, that sigma level concept really is the basis of Six Sigma. 
    Now…given that…if your furnace has a specified window of operation in place to assure acceptable quality (i.e., no defects) of what comes out of it….and if overloading it causes temperature(s) outside that specified window, then — yes — you would want to take steps to reduce the temperature variation because it is incapable with respect to the existing specified limits and excursions outside those specified limits are possible at an unacceptable level. 
    You can try to complicate it, but that’s really all there is to it (…i.e., it’s about NOT producing defects). 
    Andejrad Ich

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