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Maintenance Plans and Tasks:

Maintenance Plans and Tasks: Eliminating Non-Value Added Maintenance Activities for Improved Reliability. Robert Wiggins Showa Denko Carbon, Inc Maintenance Planning and Scheduling Supervisor.

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Maintenance Plans and Tasks:

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  1. Maintenance Plans and Tasks: Eliminating Non-Value Added Maintenance Activities for Improved Reliability Robert Wiggins Showa Denko Carbon, Inc Maintenance Planning and Scheduling Supervisor

  2. Robert Wiggins is a graduate of Trident Technical College with a diploma in the Industrial Electrical program and holds a BS degree in Business Administration/Management from Limestone College. He has over 27+ years experience with Showa Denko Carbon, Inc. (SDKC) and working in industrial maintenance and manufacturing. Robert joined SDKC in 1984 as a shift electrician. He has served as a maintenance supervisor, planner and planner-scheduler.  Robert currently serves as the maintenance planning and scheduling supervisor and is responsible for managing four maintenance planners, and the maintenance planning and scheduling activities for 37 technicians and numerous contractor services.  Robert is actively involved with updating and creating maintenance items, tasks, and maintenance plans, as part of a reliability effort to establish an SAP database maintenance library for routine and corrective type maintenance activities.

  3. QUALITY SERVICE RELIABILITY GLOBAL CAPABILITY Omachi, Japan Ridgeville, SC Tokyo, Japan

  4. QUALITY SERVICE RELIABILITY MARKET PLACE GRAPHITE ELECTRODES GRANULAR GRAPHITE FINE CARBONS

  5. QUALITY SERVICE RELIABILITY GRAPHITE ELECTRODES Large-Diameter Ultra High Powered Graphite Electrodes used in the Electric Furnace Steelmaking Industry

  6. QUALITY SERVICE RELIABILITY QUALITY SERVICE RELIABILITY GRANULAR GRAPHITE HIGH PERFORMANCE GRAPHITE FOR AUTOMOTIVE & INDUSTRIAL APPLICATIONS • Friction Materials • Lubricants • Conductive Coatings • Carbon & Graphite Shapes

  7. QUALITY SERVICE RELIABILITY FINES CARBON GRAPHITE TECHNOLOGIES FOR ADVANCED ENERGY SYSTEMS • Vapor Grown Carbon Fiber • Shape Controlled Micro Graphite Powder • Impervious Graphite Composite Plate • Ultra Fine Graphite Powder

  8. QUALITY SERVICE RELIABILITY CORPORATE HISTORY Construction of Ridgeville plant Shipment of first 28” electrodes PIP plant expansion KDAC plant expansion Over $100 million sales Over $200 million sales Shipment of first 24” electrodes Acquired by Showa Denko KK ISO9002 registration Shipment of first 30” electrodes Shipment of first 32” electrodes 1982 1983 1985 1988 1990 1995 1996 1997 2006 2008

  9. QUALITY SERVICE RELIABILITY RAW MATERIALS • Petroleum Needle Coke • Binder Pitch • Iron Oxide • Stearic Acid Petroleum Refinery Steel Pickling Process Distillation Process

  10. PROCESS OVERVIEW QUALITY SERVICE RELIABILITY Needle Coke Storage Formulate Screen Binder Pitch Mix Petroleum Pitch Impregnate Bake Extrude • Iron Oxide Rebake Machine Graphitize

  11. QUALITY SERVICE RELIABILITY SAP RELEASE 4.7

  12. Maintenance Plans and Tasks: Eliminating Non-Value Added Maintenance Activities For Improved Reliability Robert Wiggins Showa Denko Carbon, Inc Maintenance Planning and Scheduling Supervisor

  13. Preventative Maintenance Plans and Tasks: • Eliminating Waste • Increasing Value and Reliability

  14. QUALITY SERVICE RELIABILITY Inspect??? Check??? Verify??? Ensure???

  15. QUALITY SERVICE RELIABILITY Inspect??? Check??? Verify??? Ensure???

  16. QUALITY SERVICE RELIABILITY Update Procedures Combine Tasks Adjust Frequencies Change Crew Assignments

  17. QUALITY SERVICE RELIABILITY Update Procedures Combine Tasks Adjust Frequencies Change Crew Assignments

  18. QUALITY SERVICE RELIABILITY • Maintenance Frequencies Poorly Identified Maintenance Tasks Assigned With No Procedures Incorrect Labor & Craftsmen Identified Production Equipment Not Properly Prepared For Service Shutdown Requirements Not Adequately Identified Duplication Of Maintenance Tasks.

  19. 15-20% Of PM Tasks Issued To Maintenance Technicians Are Most Likely Performed By Operators As Part Of Their SOP First Pass To Pick The Low Hanging Fruit: Review All Maintenance Plans/Task To Determine The Actual Job Requirement. Second Pass: Review All Maintenance Plans/Task Procedures For Duplications. QUALITY SERVICE RELIABILITY

  20. QUALITY SERVICE RELIABILITY Change!!! Replace!!! Adjust!!! Document!!!

  21. QUALITY SERVICE RELIABILITY Change!!! Replace!!! Adjust!!! Document!!!

  22. Run To Failure: Carrying Critical Spares And Long Lead Items. Some Equipments May Be More Cost Effective To Allow To Run to Failure Than Spend Labor on Inspections. Inspecting Belts, Sheaves, Chains, Sprockets – Versus Periodic Replacement Based On Mfg Data And Known Failure Rates Review Tasks For Measurement Points and Adjustments. Make certain This Information Is Documented In The PM Text. QUALITY SERVICE RELIABILITY

  23. What Do You Expect To Gain From Your Preventative Maintenance Program? QUALITY SERVICE RELIABILITY • Safety: Safety And Health Is Priority For People And Equipment • Visibility: Well Maintained Equipment Looks Good • Availability: Equipment Runs On Demand • Reliability: People – Processes – Equipment • Maintainability: Ease Of Maintenance • Profitability: Low Maintenance Cost Per Production Unit • Sustainability: Provides Improved Maintenance Program For Future Workforce

  24. Maintenance Item Descriptions Should State The Expected Outcome Of The Order • Item Descriptions Should Be Standardized For Consistency QUALITY SERVICE RELIABILITY

  25. Maintenance Task Operations Should Be Titled To Indicate The Exact Task Assignment • Tasks Should Be Broken Out By Craft And By Sequence Of Order • Each Operation Has Correct Estimate Of Labor Required QUALITY SERVICE RELIABILITY

  26. QUALITY SERVICE RELIABILITY

  27. QUALITY SERVICE RELIABILITY

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  32. QUALITY SERVICE RELIABILITY Purpose Statement: Why is job being requested Drawings Special tools and Equipment

  33. QUALITY SERVICE RELIABILITY Safety Procedure Maintenance Procedure

  34. QUALITY SERVICE RELIABILITY Maintenance Procedure Details Exact Requirements For Completing Task

  35. QUALITY SERVICE RELIABILITY Maintenance Procedure

  36. QUALITY SERVICE RELIABILITY Equipment Checkout Housekeeping

  37. QUALITY SERVICE RELIABILITY Materials

  38. What is a Maintenance Task? QUALITY SERVICE RELIABILITY

  39. What is a Maintenance Task? QUALITY SERVICE RELIABILITY Anything pertaining to the necessary basic support andrepairof equipment. In SAP: A maintenance task is any singlemaintenance activity.

  40. What is a Maintenance Task? • Tasks Such As: • Lubrications • Infrared Thermo Graphics • Vibration Analysis • Inspections • Corrective Type Repairs • Electrical - Replacement of motor • Mechanical – Replacement of gearboxes • Mobil - Replacement of batteries • HVAC – Replacement of filters • Welding - Containers QUALITY SERVICE RELIABILITY

  41. What is a Maintenance Task? • Tasks Such As: • Adjustments • Rebuilds • Predictive Monitoring & Analyzing • Wear Based Component Replacements • Sheaves / Belts • Sprockets / Chains • Shaft Seals • Armor Plates QUALITY SERVICE RELIABILITY

  42. Maintenance Tasks Importance? QUALITY SERVICE RELIABILITY • Knowledge Transfer • Write maintenance task to document the knowledge acquired by your senior maintenance technicians, planners and staff before they retire • Write maintenance tasks to reduce “reinventing the wheel” • Planners and Technicians can issue orders from tasks quickly

  43. QUALITY SERVICE RELIABILITY • Write maintenance tasks to help bring your new maintenance force up to same level of expertise as existing maintenance personnel and quickly reduce learning curve. • SAFETY FIRST!! • Write maintenance tasks to eliminate safety issues for employees and equipment. • Reduces unexpected incidents.

  44. QUALITY SERVICE RELIABILITY • Maintenance Frequencies Properly Aligned Maintenance Tasks With Well Defined Procedures Correct Labor & Craftsmen Identified Production Operations Established On Maintenance Plans To Properly Prepared For Service Shutdown Requirements Properly Identified Duplication Tasks Eliminated

  45. QUALITY SERVICE RELIABILITY Thank You for your attention and interest! Questions?

  46. QUALITY SERVICE RELIABILITY Robert Wiggins Showa Denko Carbon, Inc rwiggins@sdkc.com

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