Basic Equipment Care

Basic Equipment Care Webinar Series: Defect Elimination

Defect Elimination is the third and final recording from Marshall Institute's and facilitiesnet.com's webinar. Senior Consultant Mark Jolley delivered the webinar for Trade Press Media, the operators of facilitiesnet.com and Maintenance Solutions Magazine titled "7-Steps to Implementing Basic Equipment Care." The two previous posts covered the 7-Stepsand the 5S'.

Today we'll cover Defect Elimination.


Click the video image below to play the short recorded webinar snippet covering the main elements of defect elimination.

Basic Equipment Care Webinar Series: 5S

Marshall Institute senior consultant Mark Jolley delivered a webinar for Trade Press media, the operators of facilitiesnet.com and maintenance solutions magazine titled "7-Steps to implementing basic equipment care". in the last post we covered the defect elimInation (hyperlink to previous post)

Today we'll cover 5S:

  • Sort
  • Set in Order
  • Shine
  • Standardize
  • Sustain

Click the video image below to play the short recorded webinar snippet covering the main elements of 5S

Basic Equipment Care Webinar Series: 7 Steps To Effective BEC

Marshall Institute senior consultant Mark Jolley delivered a webinar for Trade Press media, the operators of facilitiesnet.com and maintenance solutions magazine titled "7-Steps to Implementing Basic Equipment Care".

In three blog posts we'll release 3 recorded short snippets from the webinar:

  • 7 steps to BEC
  • Defect elimination
  • 5S

Today we'll cover 7 Steps to BEC:

1.) Perform Initial Cleaning
2.) Address Contamination Sources
3.) Establish Cleaning & Lubrication Standards
4.) Inspect Equipment
5.) Improve Process Knowledge
6.) Improve Workplace Organization
7.) Sustain Basic Equipment Care

Tidy Up Your TPM

Fall is in the air. The nights are getting cooler, the days are getting shorter, and the leaves are starting to change colors here in the Mountains of North Carolina. Fall has always been my favorite season for many reasons; including, Friday night High School football games, County fairs, church BBQ’s and most of all deer season!

Fall is also a great time to re-evaluate your TPM/TPR processes. To help self-evaluate your processes ask yourself these key questions:

Cars as an example of Basic Equipment Care

When we consider the Total Productive Maintenance process, specifically operator care, it is often helpful to use the analogy of how we should maintain our vehicle.  Car MaintenanceThe operator of the vehicle has certain responsibilities that if neglected will result in lower performance and possible catastrophic loss.  Clearly the operator has the responsibility to maintain fluid levels (gas, oil...), proper tire pressure, cleanliness of the vehicle, and report any abnormal noises, warning lights, or performance.  The operator does not need to be a mechanic, but does need to take ownership to ensure the proper service is performed.

Basically, the cost of maintaining equipment is directly correlated to the experience, ownership, and knowledge of the operator.  If you wish to test this theory, hand your car keys to your 17 year old son!! When my son was 17, even with repeated warnings, he didn't learn not to follow the car in front of him so closely. He finally learned the lesson when I got to buy a shiny new hood and bumper for my car. 

Lessons of Operator Equipment Knowledge from the Boise State Police

Often when I talk to groups about the importance of operator training and skills, I relate a story that happened to me in Boise Idaho back in 1999.  I use this real life missive to communicate the value of know how systems work as an operator....

I was conducting a Basic Equipment Care workshop in Boise, Idaho; I decided to attend a church service.  It was Wednesday night, I had no particular plans and this very large fellowship - around 1000 people - had a service with an awesome band.

Basic Equipment Care Savings - Capture and Report

A  Basic Equipment Care Workshop (BEC) is a powerful event.  It can literally transform people’s behaviors and way of thinking – turning skeptics into believers.  BEC events usually consist of a cross-functional team whose goal is to improve the reliability of a specific piece of equipment. This is done by identifying and repairing defects, as well as designing and implementing improvements and countermeasures. In addition to reliability improvements, BEC events are great for establishing a “team-based” Teamworkculture and strengthening operator ownership.

Often just by having all of the equipment Operators, Engineers and Maintenance personnel working together in a team environment, defects that cause unscheduled breakdowns or minor stoppages are identified and repaired.  By eliminating possible causes for unscheduled breakdowns and minor stoppages there are monetary savings with improved equipment uptime, production output, product quality, SMED (Single Minute Exchange of Dies) improvements, and standardization of both operations and maintenance tasks.

Frontline Supervisors are Key to Continuous Improvement

Supervisors and team leaders are crucial to Continuous Improvement (CI) efforts.  The reason is that often it is a frontline supervisor who provides personnel time to particip

ate on the CI teams as well as the production equipment for the Basic Equipment Care (BECWs) workshops. Supervisors do this at the expense of their own production goals.

In return for their support of the company's continuous improvement goals, they often are left out of the CI team.

Supervisors are often kept out of ‘the loop' because some believe that by including a supervisor on a BEC team their mere presence may inhibit participation and idea sharing as their subordinate team mates become subservient to their thoughts and ideas. A solution to this possible problem is to ensure that the supervisor participates on teams that are not associated with their area of responsibility. Even so, this alone is no reason to exclude such an important individual.