Unplanned repairs vs. planned repairs

Options

What's the impact of unplanned repairs on budget and your team morale versus planned repairs?

Comments

  • Scott Reed
    Options

    No doubt there are costs related to catastrophic failures and potential for collateral damage and serious safety ramifications. Unplanned downtime interrupts the supply chain schedule, end-to-end, plan, source, make & deliver. Costs to mobilize skilled craft, contract labor, specialized equipment and expediting parts (not on hand?), not to mention working around schedules and lead times, can be significant. All of this can have a huge impact on morale as production performance becomes unpredictable, fingers get pointed and ultimately operational goals/metrics tied to a performance bonus are missed.

    It would be great to hear some stories shared where the application of Augury Machine Health has improved moral in the workplace.

  • One of the hard things on the budget impact side is that the mitigated downtime events aren't immediately realized. It can take years to see those efforts come to fruition. That being said, there is lots of value in utilizing the data to use man-hours more efficiently.

    I think that some of the largest impacts and benefits that we see from planned repairs around Augury are around the ability to prioritize equipment repairs. Many times, the issues that the Augury team brings up and get discussed in our recurring calls are not imminent failures or actively impacting product health. This allows our maintenance team to assess those risks and prioritize addressing those issues, which puts them at a significant advantage instead of simply reacting to catastrophic failures.

    A simple example of a morale boost from one of our reliability engineers:

    "New motor failed internally approximately 10 days after installation. We were able to locate the part and have the team on standby and ready for the production team. They executed a workaround for production while the motor was replaced. On that day, the plant set a new record for a 24hr period of production output. That wouldn't have happened otherwise with this motor failing and our ability to plan around it."

  • Amy Marchesi
    Options

    @Scott Reed @Alexander Pastor appreciate the thoughtful responses on this one. Alexander, thanks for sharing a specific example - always great to see and hear a real life story about how technology is improving morale. We'll definitely look to cultivate more to show the softer / less quantifiable impact that Machine Health can have on the people using it.

  • Scott Reed
    Options

    I also think that operations need to be conscious of being able to roll up costs that differentiate planned versus unplanned downtime. If they aren't measuring and tracking, then it all gets lost in the shuffle of their reliability excellence journey which can actually result in an increased budget (labor, parts, obsolete inventory, training, consultants, etc.) until sufficient learnings, expertise and application of RX tools/programs begin to realize these reductions.

Categories