Joint reward system drives results and team work.One of the reasons many reliability and maintenance improvement initiatives fail to deliver sustained results is lack of teamwork between and within departments. Many operations and maintenance staffs still do not work as the teams they should be. The engineering department is sometimes described as "the black hole" by the maintenance staff "This is where we send drawings to be updated, and we never see them again" is a common comment. It is a given that all people in a pulp and paper mill should work for the same goal--to competitively manufacture a quality product on time. This can be measured in Overall Production Efficiency or Production Reliability or Prime Tons/Cost. If these overall measurements are applied to all departments and coupled with each department's measurement and reward systems, an organization stands a better chance of working in collaboration towards the same goal. This is, however, not always the case. Why? Ask yourself what the most important accomplishment is for a: * Project manager * Operations manager See datacenter manager. * Maintenance manager * Storeroom manager A project manager is rewarded if a project is done on time and at the lowest cost. Lowest cost seldom includes the future total cost of ownership; therefore, a mill might end up with substandard substandard, adj below an acceptable level of performance. equipment, no documentation, and no relevant training in operating and maintaining equipment. This leads to higher operations and maintenance costs--but that is not the project manager's problem! An operations manager is rewarded if production throughput is improved (improved reliability) and if operating costs operating costs npl → gastos mpl operacionales are reduced. Maintenance costs are not always the operations manager's responsibility. A maintenance manager is rewarded if maintenance costs are going down. Of course the "politically correct politically correct Politically sensitive adjective Referring to language reflecting awareness and sensitivity to another person's physical, mental, cultural, or other disadvantages or deviations from a norm; a person is not mentally retarded, but " thing to say is that it is more important to keep equipment running, but many maintenance managers know they may be in more trouble if they overspend o·ver·spend v. o·ver·spent , o·ver·spend·ing, o·ver·spends v.intr. To spend more than is prudent or necessary. v.tr. 1. the maintenance budget than if equipment reliability suffers. A storeroom manager is rewarded if he/she manages to lower inventory value. While this leads to the value of "official" stores being reduced, workers often start keeping stores in their own areas. This raises the real total cost for spare parts Spare parts, also referred to as Service Parts is a term used to indicate extra parts available and in proximity to the mechanical item, such as a automobile, boat, engine, for which they might be used. Spare parts are also called “spares. and material by "hiding" them in maintenance costs. Waste in the form of downtime and waiting time for maintenance people because of missing spare parts and material is also hidden in other departments. A better measurement would be the following: With maintained service level of 97%, reduce inventory value. The above examples are common. These reward systems do not promote true and necessary collaboration between departments. If an organization is serious about a closer integration of departments, reward systems must be designed to drive everyone's actions and performance toward the same goal. Here are some examples: Results measurements All results are outcomes of actions: * Operations, Maintenance, Engineering and Stores are all measured and rewarded by Overall Production Efficiency (production reliability) and Total Manufacturing Costs. Action measurements * MTBB MTBB Mean Time Between Breakdowns -- Mean Time Between Breaks for a paper machine. This is a joint measurement between operations and maintenance. * Trend of average vibration levels--Joint measurement between operations and maintenance. Measures operating practices and precision maintenance. * Trend of average life of common components, such as pumps, motors, and rotary steam joints. Measures operating practices and precision maintenance. * Ratio of scheduled to unscheduled shut downs--not divided by department. Joint operations A general term to describe military actions conducted by joint forces or by Service forces in relationships (e.g., support, coordinating authority) which, of themselves, do not create joint forces. and maintenance measurement. * Maintenance scheduling compliance for shut downs, including daily and weekly joint measurement between operations and maintenance. Measures how well operations and maintenance communicate and execute agreed upon Adj. 1. agreed upon - constituted or contracted by stipulation or agreement; "stipulatory obligations" stipulatory noncontroversial, uncontroversial - not likely to arouse controversy disciplines. There are many examples of how traditional maintenance measurements can become joint measurements. Paper breaks, high vibration levels, short component lives, and poor shut down performance are seldom related only to maintenance or only to operations. Therefore, these indicators should be a measurement of how well these departments work together, and should be used to encourage collaboration between departments. CHRISTER IDHAMMAR, IDCON ABOUT THE AUTHOR: Christer Idhammar is president and founder of IDCON INC inc - /ink/ increment, i.e. increase by one. Especially used by assembly programmers, as many assembly languages have an "inc" mnemonic. Antonym: dec. ., Raleigh, North Carolina For other uses of this name, see Raleigh. Raleigh (IPA: /ˈrɑli/, ral-ee) is the capital of the State of North Carolina and the county seat of Wake County. , USA. IDCON is a consulting company Noun 1. consulting company - a firm of experts providing professional advice to an organization for a fee consulting firm business firm, firm, house - the members of a business organization that owns or operates one or more establishments; "he worked for a providing worldwide education, training and implementation of better operations and maintenance practices. For more information, go to: www.idcon.com [ILLUSTRATION OMITTED] |
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