9

Fill in third segment when action is completed

(

a

k Fill in fourth " segment when refurbishment has been tested

C02 Mig Welding M/C:

Labour costs:

Total labour = £662

Parts:

New seals to clamp cylinder = £15.00

New air ducting = No cost

Water pressure gauge = £113.00

Figure 5.19 Refurbishment example for a specific machine

Step 7 Asset care

Once refurbishment of an item of equipment has been carried out, a future asset care programme must be defined to ensure that the machine condition is maintained. It is therefore necessary to establish:

• cleaning and inspection routines

• checking and condition monitoring methods and routines

• planned preventive maintenance and sendee schedules

For each of these we must develop:

• improvements to make each task easier

• visual techniques to make each task obvious

• training to achieve consistency between shifts

It is important to distinguish between natural and accelerated deterioration. In the course of normal usage, natural deterioration will take place even though the machine is used properly. Accelerated deterioration arises from outside influences. These are equipment-based, i.e. failure to tackle the root causes of dust, dirt and contamination; and operator-based, i.e. failure to maintain basic conditions such as cleaning, lubricating and bolting, and also human operational errors.

Figures 5.20 and 5.21 show how the care of assets may be broken down into elements which reflect the first three steps of the condition cycle: criticality, condition and refurbishment. Figure 5.22 illustrates the relationship between operational and technical aspects of asset care. Some key points for consideration in asset care are shown in Figure 5.23.

The question of training is developed fully in Chapter 7, but some key approaches are illustrated in Table 5.1. A training schedule form is shown in Figure 5.24. This schedule is completed through a series of single-point, on-the-job lessons.

A practical example of daily cleaning and inspection is given in Figure 5.25. This shows the checks to be made in a MJG welding cell for each shift during the working week, and records all the daily checks made by the operators. A material usage chart first developed to highlight loss measurement

Figure 5.20 Stages in asset care
Figure 5.23 Key points in asset care
Table 5.1 Role of training in asset care

Technique

Learning points

improvements

Training

Cleaning

Accelerated deterioration Cleaning is inspection

Highlight vunerability Make it easy

Video

Inspection

What is the effect?

Provide tools/equipment

Single- point lessons

Checking

Check condition Check performance

Establish standards Establish parameters

Single-point lessons

Condition

What are the signs?

Make change obvious

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