Eliott is a maintenance operator. In the industry, he is one of the most versatile players. He must adapt to all techniques in order to maintain and repair equipment and machines.
Eliott’s objective is to avoid breakdowns and production interruptions through preventive maintenance.
A multi-skilled position with multiple missions.
– Analyze and organize to anticipate breakdowns
– Improve the production tool, maintenance tools and procedures
– Continuously train / be trained
As the slightest technical failure can lead to high additional costs, he/she regularly controls, monitors and maintains the equipment.
In the context of a maintenance operator, an example of a SIPOC could be:
Spare parts suppliers Tool and machinery suppliers External maintenance service providers
Requests for preventive and corrective maintenance Previous inspection and maintenance reports Preventive maintenance plans Maintenance tools and equipment Spare parts
Analysis of maintenance requests Planning and preparation for maintenance Execution of preventive and corrective maintenance Quality control and testing Documentation and reporting of completed maintenance
Repaired and operational machinery and equipment Replaced parts and used parts Maintenance and quality control reports
Machine operators and other members of the production team Plant supervisors and managers
This SIPOC can help the maintenance operator understand the stakeholders involved, the inputs and outputs of the process, as well as the interactions between different stages of the maintenance process. By using this tool, the maintenance operator can better understand the workflow and stakeholders involved, and thus improve the maintenance process to meet the needs of the plant and ensure efficient production.
Maintenance operators have several key performance indicators (KPIs) that they can use to measure their performance. Some of these KPIs include:
- Equipment Availability: This measures the percentage of time that equipment is available for use. A maintenance operator’s goal is to keep equipment downtime to a minimum, so a high equipment availability rate is a good indicator of their performance.
- Mean Time Between Failures (MTBF): This measures the average time between equipment failures. A maintenance operator’s goal is to increase the MTBF by performing regular preventive maintenance, which can reduce the frequency of equipment failures.
- Mean Time to Repair (MTTR): This measures the average time it takes to repair equipment after a failure. A maintenance operator’s goal is to reduce the MTTR by quickly identifying and repairing equipment failures to minimize downtime.
- Maintenance Costs: This measures the cost of maintaining equipment, including labor, parts, and supplies. A maintenance operator’s goal is to keep maintenance costs low while ensuring equipment is properly maintained.
- Work Order Completion Rate: This measures the percentage of work orders completed within a given timeframe. A maintenance operator’s goal is to complete work orders in a timely manner to minimize downtime.
By monitoring these KPIs, a maintenance operator can track their performance over time and identify areas where they can improve their maintenance practices to increase equipment reliability and availability while reducing costs.
Tracking machines using Andon lights?
“Andon lights” are visual indicators used in industrial workshops to signal the operating status of a production machine. They can be green to indicate that the machine is operating normally, yellow to signal an anomaly or required maintenance, and red to indicate a breakdown or stoppage of the machine. Andon lights enable operators and supervisors to quickly track the status of machines and take appropriate action to maximize production availability and quality.
The two important themes related to data analysis for a maintenance operator in these two texts are:
- Collecting and analyzing data for predictive maintenance: The use of technologies such as real-time monitoring and data analysis to anticipate potential breakdowns and perform repairs before a breakdown occurs. This method can reduce downtime and maintenance costs.
- Performance-based maintenance: The use of performance data to determine necessary maintenance based on actual machine usage, rather than relying on fixed maintenance schedules. This can allow for better allocation of maintenance resources and improve the availability of production machinery.
This job description may vary depending on the specific needs of the company and the work environment.
The role of data for a maintenance operator
Data plays an important role for a maintenance operator in several ways:
- Equipment Maintenance History: A maintenance operator can use data to track the maintenance history of the equipment they are responsible for. This includes information such as when maintenance was last performed, what was done, and any issues that were identified. This helps the operator plan future maintenance and identify potential problems before they occur.
- Equipment Performance Monitoring: Data can be used to monitor the performance of equipment in real-time. This allows the maintenance operator to identify any abnormalities or performance issues and take corrective action before they become major problems.
- Predictive Maintenance: Data can be used to implement a predictive maintenance program. This involves using data analytics and machine learning algorithms to predict when maintenance is required based on equipment performance data. This can help reduce unplanned downtime, increase equipment reliability, and reduce maintenance costs.
- Inventory Management: Data can be used to manage inventory levels of spare parts and supplies required for maintenance. This helps ensure that the maintenance operator has the right parts and supplies on hand when they are needed, reducing downtime caused by parts shortages.
In summary, data is essential for a maintenance operator to ensure equipment is maintained effectively and efficiently, reducing downtime, increasing equipment reliability, and lowering maintenance costs.