Process Stop v. Breakdown

Process Stops A Process Stop is when the production stops for a time greater than 10 minutes due to an external influence. Example: human error, lack of raw materials, quality issues, etc. Common occurrences of process stops may be a bottle jam or low fills due to incorrect settings or set up, raw material issues, etc. Abatement of Process Stops is done by developing/improving SOP’s, Work Aids, Work Instructions, SPL, Quick Wins, Quick Kaizens, etc.

Breakdowns A Breakdown is when the equipment stops for a time greater than 10 minutes due to an equipment malfunction.  For example, there is a failure within the equipment such as a chain has broken or a belt is worn and slipping and must be changed in order to operate effectively. A breakdown typically will require either a part or electrical/mechanical intervention in order to restore the equipment to operating condition. Abatement of Breakdowns is done by developing/improving PM’s tasks, PdM tasks, and other maintenance related practices driven by Breakdown Analysis

Why is it important to differentiate?? Differentiating losses delivers a faster resolution TPM aligns losses to the proper resource(s) Minor Stops - Autonomous Maintenance Pillar Process Stops – Focused Improvement Pillar Breakdowns – Professional Maintenance Pillar Builds employee empowerment and engagement

Exercise – What Type of downtime/failure is it ??? Seamer Jams for 14 mins and Maintenance is called to help clear jam Air Conveyor blower VFD trips and needs to be reset – 12 mins downtime Kister runs out of film and maintenance is called to re-wind – down 18 mins After changing over Mead machine – maintenance is called to adjust rails – down 11 mins Replace filling valve – down 12 mins Glue pot runs out of glue – down 21 mins Palletizer reflector breaks off bracket – down 13 mins Coder runs out of ink – down 32 mins – with 30 mins of re-work Lightning storm knocks out transformer – down 3 days Flavor change – down 17 mins

Exercise – What Type of downtime/failure is it ??? Seamer Jams for 14 mins and Maintenance is called to help clear jam Process Air Conveyor blower VFD trips and needs to be reset – 12 mins downtime BD Kister runs out of film and maintenance is called to re-wind – down 18 mins Process After changing over Mead machine – maintenance is called to adjust rails – down 11 mins Process Replace filling valve – down 12 mins BD Glue pot runs out of glue – down 21 mins Process Palletizer reflector breaks off bracket – down 13 mins BD Coder runs out of ink – down 32 mins – with 30 mins of re-work -Process Lightning storm knocks out transformer – down 3 days – Other/Unplanned Flavor change – down 17 mins - Planned