Reliability J&J - São José dos Campos

Asset Reliability Definition: “Reliability is the probability of an asset to achieve the user needs over a period of time, under determined conditions” The desired reliability is only achieved from the synergy of people directly involved with the asset: Operation, Maintenance, Engineering and others indirectly involved with it.

Human Reliability Definition: “The probability of performing a service or task satisfactorily by a person at any stage required in the operating system within a minimum time limit specified.”

Environment People Asset TPM TAG (5S, steps 1...) RCM, FMECA RCFA, LCC CPM TPM (5S, steps 1...) TAG

Reliability Criticality Technics Measurement Structure Training - Cont. improvement - Mnt methodology - Periodic review - RCM - FMECA - RCFA - LCC Early Mgm ME² - Reliabilty Asset Criticality Criticality analisys - MTBF MTTR Availability - Reliability Policy Supplier Interaction Engineering Interaction TAG / TPM Interaction EHS Interaction Project Management - Cost - Quality - Time - Scope - HR - Comunications - Risks - Aquisition - Integration Technical background Human Reliability

System Reliability Equipment Human factor Operator Maintenance staff

Reliability Process Management Development of projects Creation of PM Implementation of projects Implementation of FMECA or RCM Strategy definition Trainnings Criticality analysis Trainnings Monitoring Results Strategy effectiveness analysis Change Plans (PM) Service orders analysis MAP approval Feedback meetings

Production process Criticality analysis A, B, C (Critical A) RCM project (Critical A) Criticality review Redesign Improvement Predictive Searching failure task Maintenance strategy KPI´s Preventive CMMS PM Corrective (OTF) Plan review Task combination Planning and execution Procedures

Reliability Process - RCM /FMECA Identify Equipments Y A Implement RCM or FMECA 1 e 2 Evaluation of criticality >2 years? Criticality analysis B Implement RCM or FMECA 2 N C Implement manufacturer recomendations / maintenance knowledge Y Was there a change of criticality? There have been significant changes? Start the process of revising RCM or FMECA Select maintenance strategy Critical A and B: FMECA or RCM Critical C: Manufacturer recommendations. Y N N Evaluate significative changes implemented, taking into account: - Maintenance plan job (PM) Change Control Process Improvements (EUREKA) Failure analysis (5W/ RCFA) KPI: Availability (IIMM / FI), MTBF, MTTR Define: Frequency Resources Spare parts Programmingand execution PM Creation of Plans and load CMMS SAP / MAXIMO

Bottling 100 to 300 ml on a speed of 55 up to 100 bottles/min RCM2 project Filling Machine S-1 Function: Bottling 100 to 300 ml on a speed of 55 up to 100 bottles/min

Failure modes analysed S1 - RCM project Failure modes analysed Roda alimentadora (Feeding wheel) 37 Envasadora (Filler) 97 Tampadora (Capping) 50 Etiquetadora (Labeler) 109 Aplicadora de Lacre (Sealer) 42 Total 335

S1 - RCM project Maintenance strategy Summary Redesign ( Improvements ) 17 4,8% Preventive (disposal) 11 3,2% Preventive (recovering) 8 2,4% Predictive (task condition) 53 15% Searching failure task 21 5,9% Operate til Fail (OTF) 242 68,7%

Comparing old and new plans Labor Equipment Failure modes analysed Task Old plan Duration Annual (minutes) Actions RCM New plan annual Reduction (%) Roda alimentadora Feeding wheel 37 9 1536 5 1506 2 Envasadora Filler 97 68 8274 43 3564 57 Tampadora Capping 50 6981 20 1538 78 Etiquetadora Labeler 109 38 5132 25 2782 46 Aplicadora de Lacre Sealer 42 32 3857 11 540 86 Total 335 25780 9930 61

Comparing old and new plans Material cost Equipment Quantity of tasks Old plan New plan Material cost reduction (%) Roda alimentadora Feeding wheel 12 8 2 Envasadora Filler 59 33 53 Tampadora Capping 57 20 86 Totais 128 61 74

Redesign (Improvements) Function Functional failure Failure mode Cap bottles filled at a speed of 40 to 120 per minute, with torque from 3.5 to 7.0 Nm Do not cap bottles Bottles misaligned in relation to cap Failure effect Action If the jaws are misaligned, the cap does not fit properly. This can cause spillage of product or kneading the bottle. Repair time 10 minutes Provide training about adjustment to the operational group

Redesign (Improvements) Function Functional failure Failure mode Cap bottles filled at a speed of 40 to 120 per minute, with torque from 3.5 to 7.0 Nm Do not cap bottles Improper adjustment in the pan Failure effect Action Improper adjustments to set the vibration can damage the pan and stop the process Time to repair the pan is about 2 hours Create maintenance procedure to adjust appropriately the electronic parameters of the machine

KPI – IIMM (2009)

KPI - MTBF and MTTR (2009)

KPI – Maintenance Cost (2009)

Criticality Prioritization Criterias: Criticality factors based on EH&S, Quality, Planning, Utilization, Downtime, MTBF and Waste Maintenance cost Maintenance impact on OEE

Critical “A” definition Score Impact Cost ( average month ) Points 1 - baixo 1 a 6% até R$ 5.000,00 até 1000 2 - Médio >6 a 10% >R$ 5.000,00 a R$ 10.000,00 >1000 a 1500 3 - Alto acima 10% acima R$ 10.000,00 acima 1500

Confiabilidade

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