1

VALINHOS JUN 2018

 AGENDA

1. INTRODUCTION
• Last Audit Comments
• Vision, Needs and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance

2. PILLAR METHODOLOGY

3. EXPANSION
• ICE
• EWO Dove
• EWO Tallow

4. RESULTS OF THE PILAR

5. NEXT STEPS 2
VALINHOS JUN 2018
 LAST AUDIT COMMENTS

Score Evolution Comments PILLAR SUMARY

5 1. Break analysis needs to be deeper - lack of
4 detail, use 07 WCM tools. • Last Audit

3 2. Use advanced tools to simulated Comments

2 machine\equipament running • Vision, Needs

1 3. Use Best Practices from Goiânia using SIGA and Objectives

0 system. • Route Map

• KPIs and KAIs
• Radar Chart
• Governance
SCORE TARGET Pillar Methodology
• Step 01
Implemented Actions • Step 02
• Step 03
1. Team training for deeper break analysis using WCM tools
• Step 04
2. Use of advanced tools like microscope analysis, GoPro camera, endoscope, ODS simulation to simulated machine • Step 05

running • Step 06
Expansion
3. Implementing by Brasil Maintenance Team • ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

3
VALINHOS JUN 2018
 VISIONS, NEEDS AND OBJECTIVES

VISION PILLAR SUMARY

Establish a World Class Maintenance System, getting zero breakdown in Valinhos, due the lack of • Last Audit
maintenance, supported by high level knowledge of maintenance team. Comments
• Vision, Needs
and Objectives
• Route Map
NEEDS • KPIs and KAIs

• Analyze breakdowns in their "root cause"; • Radar Chart

• Implement a maintenance system to keep the equipment in their "desired state“; • Governance

• Perform maintenance to the component level; Pillar Methodology

• Develop a work process that supports all the knowledge acquired; • Step 01

• Transfer knowledge and activities to the team of Autonomous Maintenance. • Step 02

• Step 03
• Step 04
OBJECTIVES • Step 05
• Step 06
• Eliminate unplanned maintenance activities; Expansion
• Have long-term visibility, detailed planning of maintenance; • ICE
• Operate in the highest level of efficiency and plant availability, making it economically viable. • EWO Dove
• EWO Tallow
Pillar Results
Next steps

4
VALINHOS JUN 2018
ROUTE MAP

2016 2017 2018 2019 2020

AUDIT 1ª 2ª 3ª 4ª 5ª 6ª 7ª 8ª 9ª
PILLAR SUMARY
Audit Audit Audit Audit Audit Audit Audit Audit Audit
SCORE • Last Audit
0 1 2 3 3 3 3 3 3
Comments
• Vision, Needs
and Objectives

STEP • Route Map

LEVEL. 6
and level • KPIs and KAIs
STEP. 2

STEP. 3

STEP. 4

STEP. 5

STEP. 5

STEP. 6

STEP. 6

STEP. 7

STEP. 7
LEVEL. 2

LEVEL. 2

LEVEL. 4

LEVEL. 4

LEVEL. 5

LEVEL. 5

LEVEL. 5

LEVEL. 6
• Radar Chart
• Governance
Pillar Methodology
Step 6 Step 6 Step 7 Step 7 Step 7 Step 7 • Step 01
Step 1 Step 3 Pelletizer Pelletizer Pelletizer Pelletizer Pelletizer Pelletizer • Step 02
PILLAR

100% AA 50% AA Step 4 Step 5 Step 6 Step 6 Step 7 Step 7

• Step 03
50% AA Pakmatic Pakmatic Pakmatic Pakmatic Pakmatic
OBJETIVE

TH3 • Step 04
Step 3 TH3 TH3 TH3 TH3
50% A Step 4 Step 5 Step 5 Step 6 Step 6 • Step 05
75% AA 50% AA 75% AA 50% AA 50% AA • Step 06
Step 3 Step 3 Step 3 Step 4 Step 4 Expansion
50% A 60% A 65% A 50% A 75% A • ICE
• EWO Dove
• EWO Tallow
involvement

Pillar Results
Next steps

29% 29% 60% 78% 100%

5
VALINHOS JUN 2018
 KAIs E KPIs

INDICATOR UNIT TGT (MM) TGT(AA EXP) PILLAR SUMARY

• Last Audit

OEE % 0 0 Comments
• Vision, Needs

MTBF Horas > 5000 > 5000 and Objectives

KPI
• Route Map

BREAKDOWN Lack of
• KPIs and KAIs

maintenance
# 0 0 • Radar Chart
• Governance
Pillar Methodology
MAINTENANCE COST REDUCTION % > 50 > 50 • Step 01
• Step 02

RED TAGS % 100 100 • Step 03

• Step 04

EWO COMPLETED % 100 100 • Step 05

KAI
• Step 06
Expansion
MACHINE LEDGER % 100 100 • ICE
• EWO Dove

5’S ASSESSMENT (Wharehouse % > 90 > 90

• EWO Tallow
Pillar Results
and Maintenance Workshop)
Next steps

6
VALINHOS JUN 2018
RADAR CHART – Lider Development Plan

PILLAR SUMARY
• Didatic material studies -7 steps
pilar pm
• Last Audit
• WS pm in Goiânia (carlos suchil)
Comments
• Lecture prof. yamashima
• Vision, Needs
and Objectives
Learning Style: • Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
HELPER • Step 01
• Step 02
• Step 03
• Step 04
• Reduction of storage cost in spare parts
warehouse • Step 05
• Zero breakdown in model machine
• Step 06
• Step 6 in model machine
• 21 expansion machines Expansion
• 162 pm kaizens completed • ICE
• 65% reduction of breakdown
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

7
VALINHOS JUN 2018
 RADAR CHART

Ana Thaminne Edson

Cardoso B. Cano
PM Intern
PILLAR SUMARY

• Last Audit
Comments
Wagner
• Vision, Needs
Cordeiro
PM Manager. Ednei Monteiro Rodrigo M. Donizete A. and Objectives
PM Coord. PM Analist. PM Planner 6 • Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 01
Gabriel Diego P. Klayton Priscilla • Step 02
Diego P.
Electrician PM Planner Araujo Lira
• Step 03
PM Coord.
• Step 04
• Step 05
• Step 06
• Step 07

André Expansion
Alexandre F.
Vinícius T. Amorim Carlos Mendes Mateus L.
PM Alanist. • ICE
PM Analist PM Coord. Electrician
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

Target
Dec 2017
Jun 2018 8
VALINHOS JUN 2018
 GOVERNANCE

Projec
Pillar
Supply Manage WCM Pillar t Blue
Meeting Name What? Leade
Leader rs Team Team Leade Collars PILLAR SUMARY
rs
rs
• Last Audit
PERFORMANCE Comments
PRÉ-FOS STRATEGY
DAYLY

• Vision, Needs
and Objectives
PERFORMANCE
FOS STRATEGY
• Route Map
• KPIs and KAIs
• Radar Chart
SECRETARY METHOD
• Governance
Pillar Methodology
KPI’s / KAI’s
• Step 01
MACHINE
• Step 02
PILLAR MEETING LEDGER
• Step 03
EWO
WEEKLY

• Step 04
5S
• Step 05
TARGETS (+1) • Step 06
INDICATORS • Step 07
COST Expansion
TEAM MEETING MAINTENANCE • ICE
PLAN/FAILURE • EWO Dove
ANALYSIS/PILLAR • EWO Tallow
S ACTIONS Pillar Results
Next steps
MONT

FOLLOW UP
HLY

WCM COMITE

9
VALINHOS JUN 2018
 PILLAR METHODOLOGY

MM PILLAR SUMARY

Step7 • Last Audit

Comments
EXP Step 6
Maintenance cost • Vision, Needs
management
Step 5 and Objectives
Build a predic- Establishment of • Route Map
a planned
EXP Step 4
tive mainte-
maintenance
• KPIs and KAIs
Step 0 Build a periodic nance system • Radar Chart
maintenance (trend system
• Governance
system) management)
Preliminary Step 3 Countermeasures
Pillar Methodology
• Step 01
Activities against weak
Step 2 points
• Step 02
Establishment of of the machine • Step 03

Step 1 maintenance and • Step 04

Reverse standards lengthened equip- • Step 05
deterioration ment life • Step 06
Elimination of forced (breakdown analysis) • Step 07
deterioration Expansion
and prevention of • ICE
accelerated • EWO Dove
deterioration • EWO Tallow
Pillar Results
Next steps

REACTIVE PREVENTIVE PROACTIVE

10
VALINHOS JUN 2018
 STEP 0 – PRELIMINARY ACTIVITIES
Maintenance 2 CMMS Application and 3
Budget, KPI and KAI
1
Strategy Maintenance Planning Management

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
“SAP acquisition in PC” Pillar Methodology
• Step 0
Spare Parts Management and 5S -
4 5S - Workshops 5 Lubricants Management 6
Warehouse
• Step 01
• Step 02
• Step 03
• • Step 04
• • Step 05
47%
• Step 06
• Expansion
• • ICE
• • EWO Dove
• EWO Tallow
Inventory Value (R$ '000) Pillar Results
800 632 Next steps
600 503
R$ '000

400
182 71%
200
0
16' 17' 18' 11
Year
VALINHOS JUN 2018
 STEP 0 – PRELIMINARY ACTIVITIES

STEP 2 – Multivariate classification criteria

STEP 1 – Classify spare parts for spare parts
Classification Criteria
PILLAR SUMARY

• Last Audit

Repairable and •
Comments
Vision, Needs
Consumables and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0

STEP 4 – Determine the quantity • Step 01

STEP 3 – Layout and location of each spare part

•
•
Step 02
Step 03
• Step 04
• Step 05
• Step 06
Expansion
89% of parts • ICE

in • EWO Dove
• EWO Tallow
catalogues Pillar Results
Next steps

MTTF = 3min

12
VALINHOS JUN 2018
 STEP 0 – PRELIMINARY ACTIVITIES
STEP 6 – Computerized
Management System
Before
STEP 5 – Visual management
PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
100% • KPIs and KAIs
100% Manual
Counting
MRP • Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Direct contact with
Expansion
suppliers
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

13
VALINHOS JUN 2018
 STEP 0 – PRELIMINARY ACTIVITIES

STEP7 – Standardized spare parts

Spare parts Volcano Project
PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance

CATALOGUES Pillar Methodology

• Step 0

Spend Base • Step 01

Packages Items New Spend
Line • Step 02
39 1.406 R$ 9.2 MM
R$ 10.5 MM • Step 03
Saving • Step 04

Saving R$ 1.3 MM
€364 K •
•
Step 05
Step 06
12% Cost Reduction Off-Set Inflation – R$ 0,7
MM Expansion
Simplif. 55 Suppliers 63 Suppliers Reduction. • ICE
Cash – R$ 0,9 MM • EWO Dove
Commercial Negotiation 30 days payment
DDL 90 days
• EWO Tallow
condition.
Freight Reduction – R$
Increase 22% on freight CIF. Redution in Pillar Results
Freight 100% CIF 0,2 MM
freight costs. Next steps

Trainning, Breakdown analysis, stock C. Avoid IBM – R$ 0,13

C. Avoid. R$ 0.07 MM
optimization studies. MM

Optimization of coverage and reduction of

W. Capital R$ 0.5 MM
items in stock.
14
VALINHOS JUN 2018
 WAREHOUSE RESULTS

Baixa Estoque NPI - GBV 192k Euros

€ 3.000 1,6%
PILLAR SUMARY
1,4%
1,3% • Last Audit
1,4%
Comments
€ 2.500 Giro 6
Reduced 41% meses • Vision, Needs
€ 2.700 1,2%
€ 2.520 and Objectives

€ 1,077 m
• Route Map
€ 2.000
• KPIs and KAIs
1,0%
• Radar Chart
0,8%
• Governance
€ 1.500 0,8% Pillar Methodology

€ 1.623 • Step 0
Valinhos ICE - Evolução Spare Parts • Step 01
0,6%
€ 1.000 2000 70% • Step 02
1800 • Step 03
60%
1600 0,4%
• Step 04
1400 50%
Valores em €

€ 500 • Step 05
1200 40%
0,2% • Step 06
1000
30% Expansion
800
• ICE
€- 600 20%
0,0%
400 • EWO Dove
BDT Estoque 17' Estoque 18'
10% • EWO Tallow
200
BDT kR$ BDT/GBV (%)
0 0% Pillar Results
mai/17 jun/17 jul/17 ago/17 set/17 out/17 nov/17 dez/17 jan/18 fev/18 mar/18 abr/18 Next steps

mai/17 jun/17 jul/17 ago/17 set/17 out/17 nov/17 dez/17 jan/18 fev/18 mar/18 abr/18
Estoque 1441 1444 1450 1457 1446 1441 1450 1455 1327 1311 833 867
Consumo 14 7 28 25 8 30 16 29 122 36 524 39
1% 1% 2% 2% 1% 2% 1% 2% 9% 3% 63% 4%
15
VALINHOS JUN 2018
3D PRINTER TO SPARE PARTS

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Valor Pillar Methodology
Código Descrição Descrição
consumo • Step 0
95169672 UNIDADE , DA VALVULA ALFA LAVAL 95169672 UNIDADE , DA VALVULA ALFA
R$LAVAL
24.066,00 • Step 01
1000131239 RODIZIO,GIRATORIO,NOVEX/GM-82-BL 1000131239 RODIZIO,GIRATORIO,NOVEX/GM-82-BL
R$ 1.337,46 • Step 02
85224774 PRENSA CABO,SEW/133345 85224774 PRENSA CABO,SEW/133345 R$ 828,62
• Step 03
1000360796 CAP,DA VALV SUDMO,PENTAIR/2307265 1000360796 CAP,DA VALV SUDMO,PENTAIR/2307265
R$ 356,14
85164680 CHAVE FIM CURSO,SIEMENS/3SE3 100-1EA 85164680 CHAVE FIM CURSO,SIEMENS/3SE3
R$ 295,78
100-1EA • Step 04
85224776 PRENSA CABO,SEW/133353 85224776 PRENSA CABO,SEW/133353 R$ 143,98 • Step 05
85164253 PLACA ESPELHO,4X2",SIEMENS/5TG9 614 85164253 PLACA ESPELHO,4X2",SIEMENS/5TG9
R$ 10,00
614 • Step 06
85165050 PRENSA CABO,1/2BSP,ACTIVE SENSORS/G 1/2P 85165050 PRENSA CABO,1/2BSP,ACTIVE SENSORS/G
R$ 1,30 1/2P Expansion
85178933 ELEMENTO ELASTICO,P/ACOPL VULKAN E97/G97 85178933 ELEMENTO ELASTICO,P/ACOPLR$VULKAN
146,08 E97/G97
• ICE
85277896 SEDE,SIL,MAKITA VED/MC1859KSI 85277896 SEDE,SIL,MAKITA VED/MC1859KSI
R$ 199,78
• EWO Dove
1000094987 REPARO,DA VALV,WORCESTER/RK-44-TT-1/2POL 1000094987 REPARO,DA VALV,WORCESTER/RK-44-TT-1/2POL
R$ 320,20
• EWO Tallow
1000095257 REPARO,DA VALV,WORCESTER/RK44TT-1 1/2POL 1000095257 REPARO,DA VALV,WORCESTER/RK44TT-1
R$ 383,61 1/2POL
Pillar Results
1000095262 REPARO,DA VALV,WORCESTER/RK-44-TT-3/4POL 1000095262 REPARO,DA VALV,WORCESTER/RK-44-TT-3/4POL
R$ 761,20
Next steps
1000095263 REPARO,DA VALV,WORCESTER/RK-44-TT-1POL 1000095263 REPARO,DA VALV,WORCESTER/RK-44-TT-1POL
R$ 716,28
1000122369 ACOPLAMENTO FLEX,VULKAN/VULBRAFLEX VB-28 1000122369 ACOPLAMENTO FLEX,VULKAN/VULBRAFLEX
R$ 768,20 VB-28
1000130249 LAMINA,MONTADA,DA EMBRULHADEIRA ACMA 1000130249 LAMINA,MONTADA,DA EMBRULHADEIRA
R$ 884,97 ACMA
R$ 31.219,60

16
VALINHOS JUN 2018
 STEP 0 – PRELIMINARY ACTIVITIES

1 round cost deployment Breakdown cost by pillar

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
9 • Radar Chart
,
• Governance
8
Pillar Methodology
%
• Step 0
• Step 01
• Step 02
• Step 03
C matrix • Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

17
VALINHOS JUN 2018
 PILLAR METHODOLOGY

PILLAR SUMARY

Step7 • Last Audit

Comments
Step 6
Maintenance cost • Vision, Needs
management
Step 5 and Objectives
Build a predic- Establishment of • Route Map
Step 0 tive mainte- a planned • KPIs and KAIs
Step 4 Build a periodic nance system maintenance • Radar Chart
maintenance (trend system
Preliminary • Governance
system) management)
Activities Step 3 Countermeasures
Pillar Methodology
• Step 0
against weak
Step 2 points
• Step 01
Establishment of of the machine • Step 02

Step 1 maintenance and • Step 03

Reverse standards lengthened equip- • Step 04
deterioration ment life • Step 05
(breakdown analysis)
Elimination of forced • Step 06
deterioration Expansion
and prevention of • ICE
accelerated • EWO Dove
deterioration • EWO Tallow
Pillar Results
Next steps

REACTIVE PREVENTIVE PROACTIVE

18
VALINHOS JUN 2018
 STEP 1 –

Area equipament
Pilot Equipament Initial Cleaning
removed
PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart

We begun our mapping of • Governance

Pillar Methodology
reabilities • Step 0

Transferred to mechanical • Step 01

• Step 02
workshop Identification of the points to be recovered • Step 03
• Step 04
before
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Restoration of the conditions Pillar Results
after Next steps

19
VALINHOS JUN 2018
 PILLAR METHODOLOGY

PILLAR SUMARY

Step7 • Last Audit

Comments
Step 6
Maintenance cost • Vision, Needs
management
Step 5 and Objectives
Build a predic- Establishment of • Route Map
Step 0 tive mainte- a planned • KPIs and KAIs
Step 4 Build a periodic nance system maintenance • Radar Chart
maintenance (trend system
Preliminary • Governance
system) management)
Activities Step 3 Countermeasures
Pillar Methodology
• Step 0
against weak
Step 2 points
• Step 01
Establishment of of the machine • Step 02

Step 1 maintenance and • Step 03

Reverse standards lengthened equip- • Step 04
deterioration ment life • Step 05
(breakdown
Elimination of forced • Step 06
analysis)
deterioration Expansion
and prevention of • ICE
accelerated • EWO Dove
deterioration • EWO Tallow
Pillar Results
Next steps

REACTIVE PREVENTIVE PROACTIVE

20
VALINHOS JUN 2018
 STEP 2 – BREAKDOWN ANALYSIS

MAPA DE QUEBRAS DA PELLETIZER

PILLAR SUMARY

• Last Audit
QUEBRAS POR PILAR
QUEBRAS POR PILAR
10
9
10
8 Comments
SILOS
9
8
8
7 7

• Vision, Needs
6 6
5 5
4 4

1
3 3

and Objectives
2 2
1 1
0 0

AM PM FI PD AM PM FI PD
• Route Map
• KPIs and KAIs
COMPRESSOR
PNEUMÁTICO • Radar Chart
• Governance
Pillar Methodology
• Step 0
PELLETIZER • Step 01
• Step 02

TURBO • Step 03
• Step 04
FLOW • Step 05
• Step 06
Expansion
• ICE
QUEBRAS POR PILAR QUEBRAS POR PILAR QUEBRAS POR PILAR 10
QUEBRAS POR PILAR • EWO Dove
10 10 6 9 8
• EWO Tallow
9 9
8
8 8
7
7 7
6
5
6
5
5 6
5

Pillar Results
5
4 4
4
3
1 1
3

1
3
2
1
2
1
1 2
1

Next steps
0 0
0 4

AM PM FI PD AM PM FI PD AM PM FI PD AM PM FI PD

21
VALINHOS JUN 2018
 STEP 2 – EWO PELLETIZER

Ruido excessivo no redutor da Pelletizer do JAC III, durante extrusão de noodles pelo conjunto rosca e placa
perfurada, independente da habilidade do operador e de forma constante, acarretando em uma parada PILLAR SUMARY
inesperada de 960min para intervenção.
• Last Audit
FENÔMENO
Comments
• Vision, Needs
AÇÃO and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

22
VALINHOS JUN 2018
STEP 2 – TRAINING OF MAINTENANCE TEAM

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

23
VALINHOS JUN 2018
STEP 2 – EWO DOVE MANAGEMENT

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

24 24
VALINHOS JUN 2018
 PILLAR METHODOLOGY

PILLAR SUMARY

Step7 • Last Audit

Comments
Step 6
Maintenance cost • Vision, Needs
management
Step 5 and Objectives
Build a predic- Establishment of • Route Map
Step 0 tive mainte- a planned • KPIs and KAIs
Step 4 Build a periodic nance system maintenance • Radar Chart
maintenance (trend system
Preliminary • Governance
system) management)
Activities Step 3 Countermeasures
Pillar Methodology
• Step 01
against weak
Step 2 points
• Step 02
Establishment of the machine • Step 03

Step 1 of and • Step 04

Reverse maintenance lengthened equip- • Step 05
deterioration standards ment life • Step 06
(breakdown
Elimination of forced Expansion
analysis)
deterioration • ICE
and prevention of • EWO Dove
accelerated • EWO Tallow
deterioration Pillar Results
Next steps

REACTIVE PREVENTIVE PROACTIVE

25
VALINHOS JUN 2018
STEP 3 –

STANDARD MAINTENANCE PROCEDURE

MACHINE LEDGER PELLETIZER PILLAR SUMARY

Machine Name:Formadora de caixas Creation Date:15/03/2013
Starting Date:2013
Supplier:Cermex Revising Date:
2013 KPI
MACHINE LEDGER

• Last Audit

2.- Insufficient competencies of operator or craftsman

Components AM PM
We are 2011 2010
Mês / Semanas

COMPONENT CLASSIFICATION (A,B,C)

here NOTE

Total Breakdowns N°

Total Breakdowns N°
Warehouse location

5.- Operati ve Conditi on not Observed

Sub Group

Kind of maintenance
Number

Machine condition

6.- Lack of Basi c Condition (AM)

Kind of AM cycle

Maintenance Time

(Stop; Working)

MTTR (min)

MTTR (min)
MTBF (hrs)

MTBF (hrs)
4.- Lack of Maintenance (PM)
identification
AM cycle N°

TBF (hrs)
PMcycle N°
Mach ine: Group Fr eq uen January February March April May June July August September October November December >2011

(C, I, L)

3.- Proj ect Weaknesses

(min.)

ROOT CAUSE
Picture Name Code Acti vi ty descr ipti on cy

1.- External Infl uence

[weeks]

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 26 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 REMINDER

Comments
Ki nd of Mai ntenance

A
Verificar pontos de [m in]
1 Moto redutor I TBM vazamento, vibração e 22 5 min STOP EWO
temper atura alteradas

Esteira alimentação de caixas

ROOT C AU SE
Ki nd of Mai ntenance

A
Veri ficar tensionamento e [m in]
2 Esteira I/C CBM desgates excessi vos bem 22 5 min 2 Working
EWO
como cortes super ficiais
ROOT C AU SE
Ki nd of Mai ntenance

A
Verificar lubrificação e [m in]
Mancal /

• Vision, Needs
3 Rolament o I TBM vibração 22 5min 2 Working
EWO
(desgaste no ei xo)
ROOT C AU SE

Verificar folgas nas Ki nd of Mai ntenance

B
extremidades junto aos [m in]
Rol etes
4 tracionadores I/C CBM rolamentos bem como 22 5 min 2 STOP
EWO
ranhuras em sua
super fíci e ROOT C AU SE
Ki nd of Mai ntenance
Verifi car se há folgas nos

5
Rolamentos
do redutor A I CBM
alojamentos internos e
externos e nivel de
22 15 min STOP
[m in]
EWO

Motoredutor esteira transportadora de caixas

ruído/vibração
ROOT C AU SE

and Objectives
Ki nd of Mai ntenance

A Verifi car si nais de [m in]

6 Eixo I CBM
desgastes 22 15 min STOP EWO
ROOT C AU SE

Ver ificar condições dos Ki nd of Mai ntenance

A
dentes (li vres de "pi tes" [m in]
7 En grenagem
I CBM ou pedaços quebrados). 22 15 min STOP
EWO
Verificar diâmetr o

521
primiti vo ROOT C AU SE
Ki nd of Mai ntenance

B
Veri ficar se há passagem [m in]
L

• Route Map
8 Retentor CBM de óleo entre o l ábi o do 22 2 min Working
mesmo e o eixo EWO
ROOT C AU SE
Ki nd of Mai ntenance

A
R olamento Verificar nível de vibração [m in]
9 mo tor I CBM
e si nai s de folga/desgaste
22 15 min STOP
EWO
ROOT C AU SE

PELLETIZER
Verifi car se não há sinais Ki nd of Mai ntenance

A
de perda de vácuo pelas [m in]
Braço das
10 ventosas I/C CBM conexões e ventosas e 22 5 min STOP
EWO
alinhamento do mesmo
em relação ao eixo ROOT C AU SE

• KPIs and KAIs

Verifi car fixação e Ki nd of Mai ntenance

B
alinhamento na base do [m in]
Mancal para
11 I/C CBM equi p. e possível folga do 22 5 min STOP

components
rolam ento EWO
r ol amento em seu

Extrator de caixas do magazine

al ojamento ROOT C AU SE
Ki nd of Mai ntenance
Verifi car si nais de

A
C ili nd ro desgaste ou vazamento [m in]
12 pneumático I TBM
de ar comprimido pelos
22 20 min STOP
EWO
reparos e conexões
ROOT C AU SE

Ver ificar se há sinais de Ki nd of Mai ntenance

A
folga em seu alojamento [m in]
Rótulas I CBM e na rosca de fixação na

• Radar Chart
13 1000118158 DG-03-18 12 5 min STOP
EWO
extremidade do cil indro
pneumático ROOT C AU SE

Verifi car possíveis sinais Ki nd of Mai ntenance

A
de trinca, rachadur as ou [m in]
Ventosa de
14 v ácuo
1000125514
I/L CBM desgaste excessivo nos 22 2 min STOP
EWO
l ábios de contato com as
caixas ROOT C AU SE
Ki nd of Mai ntenance
Verificar se há sinais de

A
Mangueiras [m in]
trinca, desgaste
15 pneumáticas 1000187736 PB -01-10 I CBM
excessivo ou vasamento 22 15 min STOP EWO
PK6
de ar comprimido
ROOT C AU SE

• Governance
Ki nd of Mai ntenance

A
Verificar se há sinais de [m in]
DESENHO
16 Roldanas 1000361619
DMC 75003 I/C CBM trinca, desgaste 12 5 min 4 STOP
EWO
excessivo ou quebra
ROOT C AU SE
Ki nd of Mai ntenance

Carro de transporte de caixas para armação

PELLETIZER
A
Verifi car possíveis sinais [m in]
Eixo DESENHO
17 I CBM de folga no alojamento 5min 4

PELLETIZER
excêntrico DMC 75006 22 STOP
i nterno do rolamento EWO
ROOT C AU SE
Ki nd of Mai ntenance

B
Verifi car possíveis sinais [m in]
Eixo da DESENHO
18 I CBM de folga no alojamento 12 10 min 4 STOP

Pillar Methodology
roldana DMC 75005 EWO
i nterno do rolamento
ROOT C AU SE
Ki nd of Mai ntenance

B
Eixo de Verifi car possíveis sinais [m in]
19 condução do I CBM de desgaste em por toda 12 10 min 3 STOP
EWO
carro sua extenção
ROOT C AU SE
Ki nd of Mai ntenance

A
Verifi car possíveis sinais [m in]
Garra de
20 fixação
Desenhar
I/C CBM de folga em seu conjunto 12 2 min 3 STOP EWO
arti culado
ROOT C AU SE

• Step 0
Verifi car possíveis sinais Ki nd of Mai ntenance

A
G arra de de folga na arti culação de [m in]
21 arraste de Desenhar
I/C CBM movimentação de 12 2 min 3 STOP
EWO
caixas desgaste na face de
contato com as caixas ROOT C AU SE
Ki nd of Mai ntenance
Verifi car possíveis sinais

PM21 SMP’s
B
Bucha de [m in]
DE SENHO USIN AGEM de folga no alojamento
22 alojamento I/C CBM 22 2 min 1 STOP

15 SMP’s
HAC75002 I NT ER NA externo do rolamento e no EWO
do rolamento
alojamento do atuador
ROOT C AU SE

Verifi car possíveis sinais Ki nd of Mai ntenance

A
Rolamento de folga no alojamento [m in]
23 de esfera I/C CBM externo e 22 2 min 1 STOP

• Step 01
interno,(alojamento da EWO
61805 2RSL

Atuador Rotativo
bucha e do eixo) ROOT C AU SE
Ki nd of Mai ntenance
Veri ficar se há passagem

24 Gaxeta 100013165 GR-14

A I CBM
de ar comprimido de um
l ado para outro dentro da
câmara do cilindro
22 20 min 1 STOP
[m in]
EWO
ROOT C AU SE

Calendar &
Ver ificar dentes da engrenagem Ki nd of Mai ntenance
(livres de "pites" ou quebr as) e

A
Eixo de DE SENHO USIN AGEM se seu engr enamento com a [m in]
25 acionamento HAC75004 EXT ERNA I CBM cremalheir a está dentro do 22 25 min 1 STOP EWO
diâmetro primitivo. Ver if icar
folgas em suas extr emidades ROOT C AU SE

• Step 02
Ki nd of Mai ntenance

A
Verificar dentes da [m in]
26 Cremalheira I CBM cremalheira(l ivres de 22 25 min 1 STOP
EWO
"pites" ou quebras)
ROOT C AU SE
Ki nd of Mai ntenance

Machine Ledger
Verificar pontos de fol ga

A
Braço de na articulação e [m in]
27 articulação
desenhar
I CBM
alinhamento do mesmo
22 15 min 3 STOP
EWO
em relação ao r olamento
ROOT C AU SE
Ki nd of Mai ntenance

B
Ver ificar fixação e se há [m in]
Mancal para
28 SY504 M
I/C CBM sinais de folaga no 22 5 min 3 STOP

• Step 03
rolam ento EWO
alojamento do rolamento
ROOT C AU SE

Verifi car possíveis sinais Ki nd of Mai ntenance

A
de trinca, rachadur as ou

integrated
[m in]
29 Ventosas 1000125514 PG-03-50 I/C CBM desgaste excessivo nos 4 2 min STOP
EWO
l ábios de contato com as
caixas ROOT C AU SE
Ki nd of Mai ntenance
Verifi car si nais de

B
Cilindro desgaste ou vazamento [m in]
30 Pneumático
1000124793 PG-02-50 I/C TBM
de ar comprimido pelos 22 20 min 3 STOP EWO
reparos e conexões
ROOT C AU SE

• Step 04
Ki nd of Mai ntenance
Verificar se a passagem

A
Controlador de ar comprimido está [m in]
31 de f luxo
1000116065 PG-03-36
I CBM
sendo restringida quando
22 5 min 3 Working
EWO

Formaçãoo de caixas
fechado o mesmo
ROOT C AU SE
Ki nd of Mai ntenance

A
Verificar se há folga em [m in]
32 Rótula 1000118158 DG-03-18 I CBM seu aloj amento e pino de 12 5 min 3 STOP
EWO
fixação
ROOT C AU SE
Ki nd of Mai ntenance

33 Fixação 1000124707 PG-02-54

B I/C CBM
Ver ificar fixação e se há
22 5 min 3 Working
[m in]

• Step 05
si nais de desgaste/trinca EWO
ROOT C AU SE

Verifi car possíveis sinais Ki nd of Mai ntenance

A
Mangueiras de folga na arti culação de [m in]
34 pneumáticas 1000187736 PB -01-10 I/C CBM movimentação de 22 15 min 3 STOP EWO
PK6 desgaste na face de
contato com as caixas ROOT C AU SE
Ki nd of Mai ntenance
Verifi car possíveis

B
Filtro p/ trincas, sinais de quebra [m in]
35 v ácuo I/C CBM
ou vasamento de ar 22 5 min 3 Working EWO
compri mido
ROOT C AU SE

• Step 06
Ki nd of Mai ntenance

A
Passagem interna de ar [m in]
Geradora de
36
v ácuo
1000125519 PG-04-05
I/C CBM comprimido l ivre de 22 10 min 3 STOP
EWO
impurezas
ROOT C AU SE
Ki nd of Mai ntenance

A
Verifi car se sua resposta [m in]
Válv ula
37 solenóide
PG-05-43 I/C CBM após atuação da 22 5 min 3 Working
EWO
sol enóide é rápida
ROOT C AU SE

P LAN NED MAINTENANCE

100%
OK 90%
80%

Expansion
EXTRA 70%
ACTIVITY BREAKDOWN
NOT MAINTENANCE 60%
P LAN NED 50%
40%
30%
PL ANNED MAINTENANC E
20%

A 27 ###
B 10 ###
C 0 0%

• ICE
37

• EWO Dove
• EWO Tallow
Pillar Results
Next steps

26
VALINHOS JUN 2018
 STEP 3 – RESULTS

Red Tags OEE

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
87 % and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
Breakdown and MTBF • Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove

187, 4 H
• EWO Tallow
Pillar Results
Quebra da base estrutural devido a Next steps

falta de habilidade do operador

27
VALINHOS JUN 2018
STEP 3 - RESULTS

Pelletizer JAC III

Maintenance cost + loss
PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

28
VALINHOS JUN 2018
 STEP 3 - KPI’s and KAI’s

Name 2016 YTD 2017 2017 target

PILLAR SUMARY
OEE - Pelletizer JAC3 85,79% 87,30% 95%
• Last Audit

MTBF - Pelletizer JAC3 42 h 187,4 h 5000 h Comments

KPI’s • Vision, Needs
Breakdown - Pelletizer JAC3 120 12 0 and Objectives
• Route Map
Cost - Pelletizer JAC3 R$149.855,56 R$75.846,89 R$50.000,00 • KPIs and KAIs
• Radar Chart
Name 2016 YTD 2017 2017 • Governance
Pillar Methodology
Red Tags - Pelletizer JAC3 85% 95% 95% • Step 0
• Step 01
EWO Completed - Pelletizer JAC3 100% 100% 100% • Step 02

KAI’s Machine Ledger Pelletizer JAC3 - Execution 50% 100% 100%

•
•
Step 03
Step 04

Kaizens Implemented 33 5 100 • Step 05

• Step 06
5’S Acessement 75% 69% 85% Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

29
VALINHOS JUN 2018
 PILLAR METHODOLOGY

PILLAR SUMARY

Step7 • Last Audit

Comments
Step 6
Maintenance cost • Vision, Needs
management
Step 5 and Objectives
Build a predic- Establishment of • Route Map
Step 0 tive mainte- a planned • KPIs and KAIs
Step 4 Build a periodic nance system maintenance • Radar Chart
maintenance (trend system
Preliminary • Governance
system) management)
Activities Step 3 Countermeasure
Pillar Methodology
• Step 0
s
Step 2 against weak
• Step 01
Establishment points • Step 02

Step 1 of of the machine • Step 03

Reverse maintenance and • Step 04

deterioration standards lengthened • Step 05

Elimination of forced (breakdown analysis) equip- • Step 06

deterioration ment life Expansion
and prevention of Pillar Results
accelerated Next steps
deterioration

REACTIVE PREVENTIVE PROACTIVE

30
VALINHOS JUN 2018
 STEP 4 - COUNTERMEASURES AGAINST WEAK POINTS AND
EXTENSION OF THE COMPONENT LIFE

BEFORE
Activity time= 28hs/year
600 PILLAR SUMARY

500
480 480
• Last Audit
400 Comments
290 • Vision, Needs
300
240 235
and Objectives
200
• Route Map
100 • KPIs and KAIs

0 • Radar Chart
Acesso ao Desmontagem Substituição Montagem Reinicio
componente
• Governance
Pillar Methodology
AFTER • Step 0
• Step 01
Activity time= 10h10min/year • Step 02
Saving Saving Saving Saving 600 • Step 03
R$9.312 R$1.910 R$4.492,00/ano R$2.726
• Step 04
500
• Step 05
B/C = 4,0 B/C = 5,4 B/C = 1,8 B/C = 3,9
400 • Step 06
Expansion
300
Pillar Results
200 150 150 Next steps
105 110 95
Bucha de Cilindro Válvula Contatores 100

centralizaçã Pneumático final de 0

o da rosca curso Acesso ao

componente
Desmontagem Substituição Montagem Reinicio

31
VALINHOS JUN 2018
PILLAR METHODOLOGY
“TOP 6” PARETO OF PREVENTION COSTS – STEP 3
TOTAL MAINTENANCE COST
R$ 26.643(Jun/16 – Mai/17)
PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs

STEP 4 and Objectives

• Route Map
COST • KPIs and KAIs
REDUCTION • Radar Chart

51% • Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
TOTAL MAINTENANCE COST • Step 03
R$13.209 (Jun /17 – Out/17) • Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

32
VALINHOS JUN 2018
 STEP 4 - RESULTS

PILLAR SUMARY

Breakdown and MTBF Red Tags • Last Audit

Comments
• Vision, Needs
and Objectives

5365 H • Route Map

• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

33
VALINHOS JUN 2018
STEP 4 - RESULTS

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
Total saving “Step 5” • Step 0

R$ 13.434 • Step 01
• Step 02

(51%) • Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

34
VALINHOS JUN 2018
 PILLAR METHODOLOGY

PILLAR SUMARY

Step7 • Last Audit

Comments
Step 6
Maintenance cost • Vision, Needs
management
Step 5 and Objectives
Build a predic- Establishment of • Route Map
Step 0 tive mainte- a planned • KPIs and KAIs
Step 4 nance system maintenance
Build a periodic • Radar Chart
(trend system
Preliminary maintenance • Governance
system) management)
Activities Step 3 Countermeasures
Pillar Methodology
• Step 01
against weak
Step 2 points
• Step 02
Establishment of the machine • Step 03

Step 1 of and • Step 04

Reverse maintenance lengthened equip- • Step 05

deterioration standards ment life • Step 06

Elimination of forced (breakdown analysis) • Step 07

deterioration Expansion
and prevention of • ICE
accelerated • EWO Dove
deterioration • EWO Tallow
Pillar Results
Next steps

REACTIVE PREVENTIVE PROACTIVE

35
VALINHOS JUN 2018
STEP 5 – BUILD A PERIODIC MAINTENANCE
SYSTEM

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

36
VALINHOS JUN 2018
STEP 5 – BUILD A PERIODIC MAINTENANCE
SYSTEM

Training Team

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

37
VALINHOS JUN 2018
 STEP 5 – BUILD A PERIODIC MAINTENANCE
SYSTEM
CONJUNTO PM AM
Painél 1 47 1
Painél 2 53 0
Painel 2 A 41 0
Painel View 53 10
Turbo Flow 57 10
Transmissão 38 3
Extrusão 1 43 8 PILLAR SUMARY
Extrusão 2 24 12
Rotativa 58 39 • Last Audit
Transp. Penum. 78 68 Comments
TOTAL PM 492
• Vision, Needs
TRANSFERIDO AM 151 ITENS BOTOEIRA DE EMERGÊNCIA and Objectives
PAINEL VIEW CHAVE SELETORA • Route Map
• KPIs and KAIs
DOBRADIÇA BOTÕES
VÁLVULAS DE EXAUSTÃO • Radar Chart
• Governance
MEDIDOR DE VAZÃO
TRAVA Pillar Methodology
FLANGES • Step 0
• Step 01

LUMINÁRIAS LUBRIFICADOR • Step 02

MANGOTES • Step 03
• Step 04
• Step 05
BUCHAS DAS ROSCAS
• Step 06
CHAVE GERAL PORCAS Expansion
ABRAÇADEIRA • ICE
PARAFUSOS
• EWO Dove
• EWO Tallow
Pillar Results
TEFLONS DAS CANECAS Next steps
CONTROLADOR
MANÔMETROS PARAFUSOS
VÁLVULAS
VÁLVULA DE SEGURANÇA MICRO DE SEGURANÇA
ISOLAMENTOS
MANGUEIRAS 38
VALINHOS JUN 2018
STEP 5 – BUILD A PERIODIC MAINTENANCE
SYSTEM

BEFORE NEW PROCEDURE AND

AFTER PILLAR SUMARY

TRAINING TO AM • Last Audit

Some activities passed PM to AM Comments

• Vision, Needs
SMP’s TO MAINTENANCE LABOR SOP’s TO OPERATION and Objectives
BEFORE AFTER COMPONENT
SAVING • Route Map
FREQUENCE 1 MONTH FREQUENCE 1 MONTH • KPIs and KAIs
AM STANDARD • Radar Chart
PM STANDARD 20 R$720
TIME 1380min =134
23hs TIME 1380min = 23hs • Governance
Pillar Methodology
AM STANDARD
PM STANDARD 30 R$805 • Step 0
101
• Step 01

PM STANDARD 25
AM STANDARD REDUCED R$628
•
•
Step 02
Step 03
61
R$ 3.374 • Step 04

AM STANDARD • Step 05
PM STANDARD 45 R$659
72 • Step 06
Expansion
1 1
MONTH MONTH

PM STANDARD 60 AM STANDARD • ICE

R$562
112 • EWO Dove
3 MONTH 3 MONTH
• EWO Tallow
R$3.374 Pillar Results
Next steps

39
VALINHOS JUN 2018
STEP 5 – BUILD A PERIODIC MAINTENANCE
SYSTEM
Training Team PM AM

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance

Reduced of Pillar Methodology

• Step 0
labor/month • Step 01

€100 •
•
Step 02
Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

40
VALINHOS JUN 2018
 STEP 5 – BUILD A PERIODIC MAINTENANCE
SYSTEM
Maintenance Cost Pelletizer ML STEP 4
10000
9000
8000 TOTAL MAINTENANCE COST
7000
6000
R$13.209 (Jun /17 – Out/17 Labor PILLAR SUMARY
Cost R$

5000
4000 Spare • Last Audit
963
3000 Comments
2000
3048 103 2564 • Vision, Needs
1000 100 30
115
430 960 610 807 120
289 120
217 90
212 549 862 563 457 and Objectives
0 0 0 0 0 0
STEP 5 • Route Map
• KPIs and KAIs
COST • Radar Chart
REDUCTION • Governance
Itens
29% Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
TOTAL
Maintenance MAINTENANCE
Cost COST5
Pelletizer ML STEP • Step 04
R$9.416 (Nov /17 – Mai/18)) • Step 05
10000
• Step 06
9000
8000 Expansion
7000
Cost (R$)

6000 • ICE
Labor
5000 • EWO Dove
4000
3000 342 Spare • EWO Tallow
2000
1000 3048 Pillar Results
230 120 98 102
0 430 960 610 807 120
289 120
217 90
212 234
0 724
0 321
0 177
0 165
0 Next steps

Itens 41
VALINHOS JUN 2018
 STEP 5 – BUILD A PERIODIC MAINTENANCE
SYSTEM

TOTAL MAINTENANCE
Custos PelletizerCOST
JAC IIIREDUCED PILLAR SUMARY

R$60.000,00 STEP 3 TO STEP 5 • Last Audit

Comments
• Vision, Needs

Started WCM Methodology and Objectives

R$50.000,00
• Route Map
• KPIs and KAIs
STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 • Radar Chart
R$40.000,00 • Governance

TOTAL Pillar Methodology

• Step 0

R$30.000,00 REDUCED Total saving “Step 5”

•
•
Step 01
Step 02
R$ 17.226 R$ 3.792 • Step 03

65%
• Step 04
R$20.000,00 (29%) • Step 05
• Step 06
Expansion
• ICE
R$10.000,00
• EWO Dove
• EWO Tallow
Pillar Results
R$- Next steps
Jun Jul Ago Set Out Nov Dez Jan Fev Mar Abr Mai Jun Jul Ago Set Out Nov Dez Jan Fev Mar Abr Mai
2016 2017
Cost Planning Breakdown

42
VALINHOS JUN 2018
STEP 5 – BUILD A PERIODIC MAINTENANCE
SYSTEM
Red Tags OEE

OEE
97,4 % PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
Breakdown and MTBF MTTR • Step 04
• Step 05
• Step 06
Expansion
MTBF • ICE
MTTR=1181
8814 H • EWO Dove
• EWO Tallow
Pillar Results

ZERO Next steps

BREAKDOWN

43
VALINHOS JUN 2018
 PILLAR METHODOLOGY

PILLAR SUMARY

Step7 • Last Audit

Comments
Step 6
Maintenance cost • Vision, Needs
management
Step 5 and Objectives
Build a predic- Establishment of • Route Map
Step 0 tive mainte- a planned • KPIs and KAIs
Step 4 nance system maintenance
Build a periodic • Radar Chart
(trend system
Preliminary maintenance • Governance
system) management)
Activities Step 3 Countermeasures
Pillar Methodology
• Step 01
against weak
Step 2 points
• Step 02
Establishment of the machine • Step 03

Step 1 of and • Step 04

Reverse maintenance lengthened equip- • Step 05

deterioration standards ment life • Step 06

Elimination of forced (breakdown analysis) Expansion

deterioration • ICE
and prevention of • EWO Dove
accelerated • EWO Tallow
deterioration Pillar Results
Next steps

REACTIVE PREVENTIVE PROACTIVE

44
VALINHOS JUN 2018
STEP 6 - INTRODUCTION

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02

Sensor
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

45
VALINHOS JUN 2018
STEP 6 - INTRODUCTION

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

46
VALINHOS JUN 2018
 STEP 6 - INTRODUCTION

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
NEURAL • Step 04
NETWORK
CHECK VALIDATED
•
•
Step 05
Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

Mobile notification 47
VALINHOS JUN 2018
 PILLAR METHODOLOGY

EXPANSION
PILLAR SUMARY

Step7 • Last Audit

Comments
Step 6
Maintenance cost • Vision, Needs
management
Step 5 and Objectives
Build a predic- Establishment of • Route Map
Step 0 tive mainte- a planned • KPIs and KAIs
Step 4 Build a periodic nance system maintenance • Radar Chart
maintenance (trend system
Preliminary • Governance
system) management)
Activities Step 3 Countermeasures
Pillar Methodology
• Step 0
against weak
Step 2 points
• Step 01
Establishment of of the machine • Step 02

Step 1 maintenance and • Step 03

Reverse standards lengthened equip- • Step 04
deterioration ment life • Step 05
(breakdown analysis)
Elimination of forced • Step 06
deterioration Expansion
and prevention of • ICE
accelerated • EWO Dove
deterioration • EWO Tallow
Pillar Results
Next steps

REACTIVE PREVENTIVE PROACTIVE

48
VALINHOS JUN 2018
 STEP 1 EXPANSION - ICE

PAKMATIC TH03
PRINCIPIO DE MOVIMENTO CONJUNTO EMPILHADOR DE POTES
PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

49
VALINHOS JUN 2018
 STEP 1 EXPANSION - ICE

PAKMATIC TH03
PRINCIPIO DE MOVIMENTO CONJUNTO EMPILHADOR DE POTES
PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

50
VALINHOS JUN 2018
 PILLAR METHODOLOGY

EXPANSION
PILLAR SUMARY

Step7 • Last Audit

Comments
Step 6
Maintenance cost • Vision, Needs
management
Step 5 and Objectives
Build a predic- Establishment of • Route Map
Step 0 tive mainte- a planned • KPIs and KAIs
Step 4 Build a periodic nance system maintenance • Radar Chart
maintenance (trend system
Preliminary • Governance
system) management)
Activities Step 3 Countermeasures
Pillar Methodology
• Step 0
against weak
Step 2 points
• Step 01
Establishment of of the machine • Step 02

Step 1 maintenance and • Step 03

Reverse standards lengthened equip- • Step 04
deterioration ment life • Step 05
(breakdown
Elimination of forced • Step 06
analysis)
deterioration Expansion
and prevention of • ICE
accelerated • EWO Dove
deterioration • EWO Tallow
Pillar Results
Next steps

REACTIVE PREVENTIVE PROACTIVE

51
VALINHOS JUN 2018
 STEP 2 EXPANSION - ICE

PAKMATIC TH03
• Equipamento/Modelo: Embaladora Overlap ZWA
40
• Fabricante: Pakmatic do Brasil PILLAR SUMARY
• Ano Fabricação: 2012 • Last Audit
• Velocidade Máxima: 40 pacotes/min Comments
• Formatos: 1L, 1,5L e 2L • Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
Servomotor • Step 04
• Step 05
• Step 06
Local da quebra Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

Conjunto transmissão

52
VALINHOS JUN 2018
 STEP 2 EXPANSION - ICE
FENÔMENO / 5W’S
Parada do servo motor principal da pakmatic TH3, durante a
transferência de potes da esteira de entrada para a corrente
PILLAR SUMARY
FENÔMENO empurradora, sem uma tendência definida e independente da
habilidade do operador/manutentor, ocasionando acumulo de • Last Audit
Comments
potes na esteira de entrada do equipamento. • Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

53
VALINHOS JUN 2018
 PILLAR METHODOLOGY

EXPANSION
PILLAR SUMARY

Step7 • Last Audit

Comments
Step 6
Maintenance cost • Vision, Needs
management
Step 5 and Objectives
Build a predic- Establishment of • Route Map
Step 0 tive mainte- a planned • KPIs and KAIs
Step 4 Build a periodic nance system maintenance • Radar Chart
maintenance (trend system
Preliminary • Governance
system) management)
Activities Step 3 Countermeasures
Pillar Methodology
• Step 0
against weak
Step 2 points
• Step 01
Establishment of the machine • Step 02

Step 1 of and • Step 03

maintenance lengthened equip- • Step 04
standards ment life • Step 05
Reverse
Elimination of forced deterioration • Step 06
deterioration (breakdown analysis) Expansion
and prevention of • ICE
accelerated • EWO Dove
deterioration • EWO Tallow
Pillar Results
Next steps

REACTIVE PREVENTIVE PROACTIVE

54
VALINHOS JUN 2018
 STEP 3 EXPANSION - ICE

PILLAR SUMARY

• Last Audit
Comments
MACHINE LEDGER PAKMATIC • Vision, Needs
Machine Name:Formadora de caixas Creation Date:15/03/2013

and Objectives
Starting Date:2013
Supplier:Cermex Revising Date:
2013 KPI
MACHINE LEDGER

2.- Insuf fici ent competencies of operat or or craf tsman

Components AM PM
We are
2011 2010
Mês / Semanas

COMPONENT CLASSIFICATION (A,B,C)

here NOTE

Total Breakdowns N°

Total Breakdowns N°
Warehouse location

5.- Operat ive Condi tion not Observed

Sub Group

Kind of maintenance
Number

Machine condition
Kind of AM cycle

Maintenance Time

6.- Lack of Basic Condi tion (AM)

(Stop; Working)

MTTR (min)

MTTR (min)
MTBF (hrs)

MTBF (hrs)
4.- Lack of Maint enance (PM)
identification
AM cycle N°

PM cycle N°

TBF (hrs)
Machine: Group January February March April May June July August September October November December

(C, I, L)
F requ en
>2011

(min.)

3.- Proj ect Weaknesses

ROOT CAUSE
Pic ture Name Code Activity descriptio n cy

1.- External Influence

[weeks]

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 26 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 REM INDER

• Route Map
Kind of Main tenance
Verificar pontos de

A
[m in]
1 Moto redutor I TBM vazamento, vibração e
temperatura alteradas
22 5 min STO P
EWO

Esteira alimentação de caixas

ROOT CAUSE
Kind of Main tenance
Verificar tensioname nto e

A
[m in]
2 Esteira I/C CBM desgates excessivos bem 22 5 min 2 Work ing
EWO
como cortes superficiais
ROOT CAUSE
Kind of Main tenance
Verificar lubrificação e

A
M ancal / [m in]
I 22 2 Work ing

• KPIs and KAIs

3 TBM vibração 5min
Rolamento EWO
(desgaste no eixo)
ROOT CAUSE

Verificar folgas n as Kind of Main tenance

extremidades junto aos

B
Rolete s [m in]
4 trac ionadore s I/C CBM rolam entos bem como 22 5 min 2 STO P
EWO
ranhuras em su a
superfície ROOT CAUSE

PAKMATIC
Kind of Main tenance

PAKMATIC
Verificar se há folga s nos

A
Rolamentos alojam entos internos e [m in]
5 do redutor I CBM
externos e nivel de
22 15 min STO P
EWO

Motoredutor esteira transportadora de caixas

ruído/vibração
ROOT CAUSE
Kind of Main tenance

• Radar Chart
A Verificar sinais de [m in]
6 Eixo I CBM
desgastes
22 15 min STO P
EWO
ROOT CAUSE
Verificar con dições dos Kind of Main tenance
dente s (livres de "pites"

A
[m in]
7 En gren ag em I CBM ou pedaços quebrados).
Verificar diâmetro
22 15 min STO P
EWO
primitivo ROOT CAUSE
Kind of Main tenance
Verificar se há passagem

B
[m in]

14 SMP’s
8 Retentor L CBM de óle o entre o lábio do 22 2 min Work ing

21 SMP’s
mesmo e o eixo EWO
ROOT CAUSE
Kind of Main tenance

• Governance
A
Rolamen to Verificar nível de vib ração [m in]
9 I CBM 22 15 min STO P

2508
mo tor e sinais de folga/desgaste EWO
ROOT CAUSE

Verificar se nã o há sinais Kind of Main tenance

A
de perd a de vácuo pelas [m in]
Braço das
10 ventosas I/C CBM conexões e ventosas e
alinhamento do mesmo
22 5 min STO P
EWO
em relação ao eixo ROOT CAUSE
Verificar fixação e Kind of Main tenance
a linham ento na base do

B
Mancal para [m in]
11 rolamento I/C CBM equip. e possível folga do
rolam ento em seu
22 5 min STO P
EWO

Extrator de caixas do magazine

alojam ento ROOT CAUSE

Pillar Methodology
Kind of Main tenance

PAKMATIC
Verificar sinais de

A
Cilindro desgaste ou vazamento [m in]
12 pn eumát ico I TBM
de ar comprimido pelos
22 20 min STO P
EWO
reparos e conexões
ROOT CAUSE
Verificar se há sinais de Kind of Main tenance
fo lga em seu alojam ento

A
[m in]
13 R ótulas 100011 8158 DG-03-18 I CBM e na rosca de fixaçã o na
extremidade do cilindro
12 5 min STO P
EWO

components
pneumático ROOT CAUSE

Verificar possíveis sinais Kind of Main tenance

A
de trinca, rachadura s ou [m in]
Ventosa de
14 vácuo
100012 5514
I/L CBM desgaste excessivo nos
lá bios de contato com as
22 2 min STO P
EWO

• Step 0
caixas ROOT CAUSE
Kind of Main tenance
Verificar se há sinais de
M anguei ras

A trinca, desgaste [m in]

15 pneumáticas 100018 7736 PB-01-10 I CBM
excessivo ou vasamento
22 15 min STO P
EWO
PK6 de ar com primido
ROOT CAUSE
Kind of Main tenance

A
DESENHO
Verificar se há sinais de [m in]
16 R oldanas 100036 1619
DMC75003 I/C CBM trinca, desgaste 12 5 min 4 STO P
EWO
exce ssivo ou que bra
ROOT CAUSE
Kind of Main tenance

Carro de transporte de caixas para armação

Verificar possíveis sinais

A
Eixo DESENHO [m in]
17 e xcêntrico DMC75006 I CBM de folg a no alojam ento 22 5min 4 STO P
EWO

• Step 01
interno do rolame nto
ROOT CAUSE
Kind of Main tenance

B
Verificar possíveis sinais [m in]
Eixo da DESENHO
18 roldana DMC75005 I CBM de folg a no alojam ento 12 10 min 4 STO P
EWO
interno do rolame nto
ROOT CAUSE
Kind of Main tenance
Eixo de Verificar possíveis sinais

B
[m in]
19 condução do
carro
I CBM de desgaste em por toda
sua ext enção
12 10 min 3 STO P
EWO
ROOT CAUSE
Kind of Main tenance

A
Verificar possíveis sinais [m in]
Garra de
3

• Step 02
20 fixação
Desenh ar
I/C CBM d e folga em seu conjunto
articulado
12 2 min STO P
EWO
ROOT CAUSE
Verificar possíveis sinais Kind of Main tenance
Garra de d e folga na articulação de

A
[m in]
21 a rraste de
caixas
Desenh ar
I/C CBM movimenta ção de
desg aste n a face de
12 2 min 3 STO P
EWO
contato com as caixas ROOT CAUSE
Kind of Main tenance
B ucha de Verificar possíveis sinais

B
DESENHO U SINAGEM de folg a no alojam ento [m in]
22 alojamento HAC750 02 INT ERN A I/C CBM
externo do rolamento e no
22 2 min 1 STO P
EWO
do rolamento
alojamento do atua dor
ROOT CAUSE
Verificar possíveis sinais Kind of Main tenance

• Step 03
Rolame nto de folg a no alojam ento

A
[m in]
23 de esfera
61 805 2RSL
I/C CBM externo e
intern o,(alojamento da
22 2 min 1 STO P
EWO

Atuador Rotativo
bucha e do eixo) ROOT CAUSE
Kind of Main tenance
Verificar se há passagem

A de ar com primido de um [m in]

24 Gaxeta 100013165 GR-14 I CBM
la do para outro dentro da
22 20 min 1 STO P
EWO
câm ara do cilind ro
ROOT CAUSE
Verificar dentes da engrena gem Kind of Main tenance
(livres de "pite s" o u quebr as) e

A
Eixo de DESENHO U SINAGEM se seu engre namento co m a [m in]
25 acionamento HAC750 04 EXT ER NA I CBM crema lheira está dentro do 22 25 min 1 STO P
EWO
diâmetro primi ti vo . Ve rificar
folga s e m suas extremida des ROOT CAUSE
Kind of Main tenance

• Step 04
A
Verificar de ntes d a [m in]
26 Cremalheira I CBM cremalheira(livres de 22 25 min 1 STO P
EWO
"pites" ou quebra s)
ROOT CAUSE
Kind of Main tenance
Verificar ponto s de f olga

A
Braço de na articulação e [m in]
27 articulaç ão
d esenhar
I CBM
alinhamento do mesmo
22 15 min 3 STO P
EWO
em rela ção ao rolamento
ROOT CAUSE
Kind of Main tenance

PM Calendar &
B
Mancal para Verificar fixação e se há [m in]
28 rolamento
SY50 4 M
I/C CBM sina is de folaga no 22 5 min 3 STO P
EWO
alojamento do rolamento
ROOT CAUSE

• Step 05
Verificar possíveis sinais Kind of Main tenance
de trinca, rachadura s ou

A
[m in]
29 Ventosas 100012 5514 PG-03-50
I/C CBM desgaste excessivo nos
lá bios de contato com as
4 2 min STO P
EWO
caixas ROOT CAUSE
Kind of Main tenance
Verificar sinais de

B
Cilindro desgaste ou vazamento [m in]
30 Pneumá tico
100012 4793 PG-02-50 I/C TBM
de ar comprimido pelos
22 20 min 3 STO P
EWO

Machine Ledger
reparos e conexões
ROOT CAUSE
Kind of Main tenance

• 1409 Component A
Verificar se a passagem

A
Controlador de ar comprim ido está [m in]
31 de fluxo
100011 6065 PG-03-36
I CBM
sendo restringida quando
22 5 min 3 Work ing
EWO

Formaçãoo de caixas
fechado o mesmo

• Step 06
ROOT CAUSE
Kind of Main tenance

A
Verifica r se há folga em [m in]
32 R ótula 100011 8158 DG-03-18 I CBM seu alojamen to e pin o de 12 5 min 3 STO P
EWO
fixação
ROOT CAUSE

integrated
Kind of Main tenance

B Verificar fixação e se há [m in]

33 Fixação 100012 4707 PG-02-54
I/C CBM
sinais de desgaste/trinca
22 5 min 3 Work ing
EWO
ROOT CAUSE

Verificar possíveis sinais Kind of Main tenance

M anguei ras

A
d e folga na articulação de [m in]
34 pneumáticas 100018 7736 PB-01-10 I/C CBM movimenta ção de 22 15 min 3 STO P
EWO

Expansion
PK6 desg aste n a face de
contato com as caixas ROOT CAUSE
Kind of Main tenance
Verificar possíveis

B
Filtro p/ trincas, sinais de quebra [m in]

• 141 Component B
35 vácuo I/C CBM
ou vasamento de ar
22 5 min 3 Work ing
EWO
comprimido
ROOT CAUSE
Kind of Main tenance

A
Geradora de Passagem interna de ar [m in]
36 vácuo
100012 5519 PG-04-05 I/C CBM com primido livre de 22 10 min 3 STO P
EWO
im purezas
ROOT CAUSE
Kind of Main tenance
Verificar se sua resp osta

A
Válvula [m in]

• ICE
37 solenóide
PG-05-43
I/C CBM após atuação da
solenóide é rápida
22 5 min 3 Work ing
EWO
ROOT CAUSE
100%
PL ANNED MAINTENANCE
OK 90%
80%
EXTRA 70%
A CTIVITY BR EAK DOWN
NOT MA INTENA NC E
60%
PLANNED 50%
40%

• 727 Component C
30%
PL ANNED MA INTENANCE 20%

• EWO Dove
A 27 ###
B 10 ###
C 0 0%

37

• EWO Tallow
Pillar Results
Next steps

55
VALINHOS JUN 2018
STEP 3 EXPANSION - ICE

Red
OEE
Breakdown Tags
and MTBF
OEE Pakmatic TH03
# Número
Resolução e principais
deEtiquetas
Quebras perdas
PMVermelhas
e MTBF relacionadas
PM Pakmatic PMa- OUT/17
TH3 - JUL/16
Pakmatic TH03 JUL/16 aa OUT/17
JUL/16 OUT/17 PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology

OEE %
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps
8- Manutenção planejada 13-Quebra/falha equipamento PAKMATIC TH03 OEE

56
VALINHOS JUN 2018
 PILLAR METHODOLOGY

EXPANSION
PILLAR SUMARY

Step7 • Last Audit

Comments
Step 6
Maintenance cost • Vision, Needs
management
Step 5 and Objectives
Build a predic- Establishment of • Route Map
Step 0 tive mainte- a planned • KPIs and KAIs
Step 4 Build a periodic nance system maintenance • Radar Chart
maintenance (trend system
Preliminary • Governance
system) management)
Activities Step 3 Countermeasures
Pillar Methodology
• Step 0
against weak
Step 2 points
• Step 01
Establishment of of the machine and • Step 02

Step 1 maintenance lengthened equip- • Step 03

standards ment life • Step 04
• Step 05
Reverse
Elimination of forced deterioration • Step 06
deterioration (breakdown analysis) Expansion
and prevention of • ICE
accelerated • EWO Dove
deterioration • EWO Tallow
Pillar Results
Next steps

REACTIVE PREVENTIVE PROACTIVE

57
VALINHOS JUN 2018
 STEP 4 EXPANSION - ICE

PILLAR SUMARY

PM COSTS AT THE END OF STEP 3 • Last Audit

Comments
BY MACHINE LEDGER
• Vision, Needs
COMPONENTS
and Objectives
• Route Map
9000 • KPIs and KAIs
• Radar Chart
8000
• Governance
IDEAL 7000 ACTUAL
CONDITION CONDITION Pillar Methodology
• Step 0
6000
• Step 01
5000 • Step 02

4000 • Step 03
7030 • Step 04
3000
• Step 05

2000 • Step 06
3200 Expansion
1000 2230 2066 1835 1780 1760 1600 • ICE

0 480 330 • EWO Dove

Cilindro Cilindro Sistema de Servo motor e Conjunto Sensores Servo motor Braço de Resistência Relé contato • EWO Tallow
pneumático pneumático tração drive rosca de buchas, atuação da indexador regulagem de mecânico2,5° Pillar Results
garras elevador potes indexador entrada rolamentos e rosca de separador de abertura da
empilhador mancais da entrada potes rosca Next steps
rosca entrada

58
VALINHOS JUN 2018
 STEP 4 EXPANSION - ICE

9000

8000

7000

6000

5000
PILLAR SUMARY
4000
7030
3000
• Last Audit
2000
3200 Comments
1000 2230 2066 1835 1780 1760 1600
0 480 330 • Vision, Needs
Cilindro Cilindro Sistema de Servo motor e Conjunto Sensores Servo motor Braço de Resistência Relé contato
pneumático pneumático tração drive rosca de buchas, atuação da indexador regulagem de mecânico and Objectives
garras elevador potes indexador entrada rolamentos e rosca de separador de abertura da
empilhador mancais da entrada potes rosca • Route Map
rosca entrada
Cilindro pneumático FESTO • KPIs and KAIs
DFM-32-50-P-A-GF
com guia lateral • Radar Chart

X
• Governance
Pillar Methodology
AFTER Cilindro pneumático FESTO • Step 0
ADVUL-32-40-P-A-GF • Step 01
com guia lateral • Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

59
VALINHOS JUN 2018
 STEP 4 EXPANSION - ICE

PILLAR SUMARY

2018 2020
• Last Audit
Comments
January February March April May June July August September October November December April May June July August
• Vision, Needs
14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
Cost • Step 06
Material R$ 2.250 MP-INFO Expansion
Cylinder R$ 4.300 • ICE
MO R$ 550 • EWO Dove
Total – R$7.100 B/C = 1,0 • EWO Tallow

Saving Pillar Results

Next steps
Cylinder R$ 7.030
TH1 e TH2(ok) - Potencial Saving
MO R$420
Total – R$ 7.450 R$808

60
VALINHOS JUN 2018
 STEP 4 EXPANSION - ICE
AFTER

9000

8000

7000

6000
2017 2022
5000
PILLAR SUMARY
4000
7030
August September October November December January February March April May June July August September October November December
3000
• Last Audit
2000
3200
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
Comments
1000 2230 2066 1835 1780 1760 1600
0 480 330 • Vision, Needs
Cilindro Cilindro Sistema de Servo motor e Conjunto Sensores Servo motor Braço de Resistência Relé contato
pneumático pneumático tração drive rosca de buchas, atuação da indexador regulagem de mecânico and Objectives
garras elevador potes indexador entrada rolamentos e rosca de separador de abertura da
empilhador mancais da entrada potes rosca • Route Map
rosca entrada
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
BEFORE Cilindro Pneumático FESTO • Step 0
DNC- 50-320-A – PPV - PPVA • Step 01
Custo de R$932,00 por peça. Servo Motor Festo EMMS-AS-100-M-HS-RMB • Step 02
1 substituições em 1 ano com tempo de vida útil estimado de 5 anos. • Step 03
devido perda de força por desgaste no (Inspeção anual – sem substituição desde • Step 04
êmbolo de acionamento assim como Julho/17)
riscos na camisa interna • Step 05
• Step 06
Expansion
• ICE
Cost
• EWO Dove
Servomotor R$ 3.200
Pay back MP-INFO • EWO Tallow
MO R$ 230
Material R$ 120 2 anos Pillar Results
Next steps
Total – R$3.550
Saving
Cylinder R$ 1.430
MO R$240 B/C = 0,4
61
Total – R$ 1.670
VALINHOS JUN 2018
 STEP 4 EXPANSION - ICE
Devido a constantes enroscos de potes causando
Componentes
muitas paradas de acionamento
para desenrosco,dafoirosca de e
discutido
entrada de potes
juntoe ao
indexador
time de com custo
9000 AFTER
BEFORE implementado projetos uma
8000
total de R$14.210 para restabelecimento
solução para alteração na concepção da entrada
7000 das
de condições ideais seguindo
potes na Pakmatic, calendário
eliminando todo o
6000
PM da Machine Ledger
mecanismo e componentes de rosca e indexador,
5000
PILLAR SUMARY
4000 substituindo por um desviador adaptado à prória
7030
3000 esteira de entrada da Pakmatic. • Last Audit
2000
3200 Comments
1000 2230 2066 1835 1780 1760 1600
0 480 330 Servomotor • Vision, Needs
Cilindro Cilindro Sistema de Servo motor e Conjunto Sensores Servo motor Braço de Resistência Relé contato
pneumático pneumático tração drive rosca de buchas, atuação da indexador regulagem de mecânico and Objectives
garras elevador potes indexador entrada rolamentos e rosca de separador de abertura da
empilhador mancais da entrada potes rosca • Route Map
rosca entrada
• KPIs and KAIs
CONJUNTO
MACHINE LEDGER PAKMATIC ROSCA ENTRADA • Radar Chart
Rosca
MACHINE LEDGER
Machine Name:Formadora de caixas
Starting Date:2013
Supplier:Cermex
Creation Date:15/03/2013

Revising Date:
2013 KPI
DE POTES transportadora • Governance
2.- Insuffi cient competencies of operator or craftsman

Components AM PM
We are
2011 2010
Mês / Semanas
COMPONENT CLASSIFICATION (A,B,C)

NOTE

Pillar Methodology
here
Total Breakdowns N°

Total Breakdowns N°
Warehouse location

5.- Operative Condition not Observed

Sub Group

Kind of maintenance
Number

Machine condition
Maintenance Time

6.- Lack of Basic Condi ti on (AM)

Ki nd of AM cycle

(Stop; Working)

MTTR (min)

MTTR (min)
MTBF (hrs)

MTBF (hrs)
identification

4.- Lack of Maintenance (PM)

AM cycle N°

PM cycle N°

TBF (hrs)

Machine: Group January February March April May June July August September October November December >2011
(C, I, L)

Fr equen
(min.)

3.- Project Weaknesses

ROOT CAUSE

Picture Name Code Activity descri ption cy

1.- External Influence

[weeks]

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 26 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 REMINDER

Kind of Maintenance
Verifi car pontos de

A
[m in ]
1 I 5 min

• Step 0
Moto redutor TBM vazamento, vibração e 22 STOP
EWO
temperatura alteradas
Esteira alimentação de caixas

ROOT CAUSE
Kind of Maintenance
Verificar tensionamento e

A
[m in ]
2 Esteira I/C CBM desgates excessivos bem 22 5 min 2 W orking
EWO
como cortes superfi ciais
ROOT CAUSE
Kind of Maintenance
Verificar lubrificação e

A
Mancal / [m in ]
3
Rolamento I TBM vi bração 22 5min 2 W orking
EWO
(desgaste no eixo)

• Step 01
ROOT CAUSE

Veri ficar folgas nas Kind of Maintenance

extremi dades junto aos

B
Roletes [m in ]
4 tracionadores I/C CBM rolamentos bem como 22 5 min 2 STOP
EWO
ranhuras em sua
superfície ROOT CAUSE
Kind of Maintenance
Veri ficar se há folgas nos

A
Rolamentos alojamentos internos e [m in ]
5
do redutor I CBM
externos e ni vel de
22 15 min STOP
EWO
Motoredutor esteira transportadora de caixas

ruído/vibração
ROOT CAUSE

CONJUNTO
Kind of Maintenance

A
• Step 02
Verificar sinais de [m in ]
6 Eixo I CBM
desgastes
22 15 min STOP
EWO
ROOT CAUSE

Verifi car condições dos Kind of Maintenance

dentes (livres de "pites"

A
[m in ]
7 Engr enagem I CBM ou pedaços quebrados). 22 15 min STOP
EWO
Verificar diâmetro
primiti vo ROOT CAUSE

INDEXADOR Rolamentos
Kind of Maintenance
Verificar se há passagem

B
[m in ]
L

• Step 03
8 Retentor CBM de óleo entre o lábio do 22 2 min W orking
mesmo e o eixo EWO
ROOT CAUSE
Kind of Maintenance

A
Rol am ento Veri ficar nível de vibração [m in ]
9 m otor I CBM
e sinais de folga/desgaste
22 15 min STOP
EWO
ROOT CAUSE

Veri ficar se não há sinais Kind of Maintenance

de perda de vácuo pelas

A
Braço das [m in ]
10
ventosas I/C CBM conexões e ventosas e 22 5 min STOP
EWO
alinhamento do mesmo

• Step 04
em relação ao eixo ROOT CAUSE

Verificar fi xação e Kind of Maintenance

ali nhamento na base do

B
Mancal para [m in ]
11
rolamento I/C CBM equip. e possível folga do 22 5 min STOP
EWO
rolamento em seu
Extrator de caixas do magazine

alojamento ROOT CAUSE

Kind of Maintenance
Verificar sinais de

A
Cil indr o desgaste ou vazamento [m in ]
12 pneum áti co I TBM
de ar comprimido pelos
22 20 min STOP
EWO
reparos e conexões
ROOT CAUSE

• Step 05
Verificar se há sinais de Kind of Maintenance
folga em seu alojamento

A
[m in ]
13 Rótulas 1000118158 DG -03-18 I CBM e na rosca de fixação na 12 5 min STOP
EWO
extremi dade do cilindro
pneumáti co ROOT CAUSE

Verificar possíveis sinais Kind of Maintenance

de trinca, rachaduras ou

A
Ventosa de [m in ]
14
vácuo
1000125514
I/L CBM desgaste excessivo nos 22 2 min STOP
EWO
l ábios de contato com as
caixas ROOT CAUSE
Kind of Maintenance
Verificar se há sinais de
Mangueiras

A trinca, desgaste [m in ]
I

• Step 06
15 pneumáticas 1000187736 PB-01-10 CBM 22 15 min STOP
excessivo ou vasamento EWO
PK6
de ar comprimido
ROOT CAUSE
Kind of Maintenance
Verificar se há sinais de

A
DESENHO [m in ]
16 Roldanas 1000361619
DMC75003 I/C CBM trinca, desgaste 12 5 min 4 STOP
EWO
excessi vo ou quebra
ROOT CAUSE
Kind of Maintenance
Carro de transporte de caixas para armação

Verificar possíveis sinais

A
Eixo DESENHO [m in ]
17
excêntrico DMC75006 I CBM de folga no alojamento 22 5min 4 STOP
EWO
interno do rolamento

Expansion
ROOT CAUSE
Kind of Maintenance
Verificar possíveis sinais

B
Eixo da DESENHO [m in ]
18 I CBM de folga no alojamento 12 10 min 4 STOP

Redutor planetário
roldana DMC75005 EWO
interno do rolamento
ROOT CAUSE
Kind of Maintenance
Eixo de Verificar possíveis sinais

B
[m in ]
19 condução do I CBM de desgaste em por toda 12 10 min 3 STOP
EWO
carro sua extenção
ROOT CAUSE

• ICE
Kind of Maintenance
Verificar possíveis sinais

A
Garra de [m in ]
20 fixação
Desenhar
I/C CBM de fol ga em seu conjunto 12 2 min 3 STOP
EWO
articulado
ROOT CAUSE

Verificar possíveis sinais Kind of Maintenance

Garra de de folga na arti culação de

A
[m in ]
21 arraste de Desenhar
I/C CBM movimentação de 12 2 min 3 STOP
EWO
caixas desgaste na face de
contato com as caixas ROOT CAUSE
Kind of Maintenance
Verificar possíveis sinais
Bucha de

B
DESE NHO USINAGEM de folga no alojamento [m in ]

• EWO Dove
22 alojamento HAC75002
INT ERNA I/C CBM
externo do rolamento e no
22 2 min 1 STOP
EWO
do rolamento
alojamento do atuador
ROOT CAUSE

Verificar possíveis sinais Kind of Maintenance

Rolamento de folga no alojamento

A
[m in ]
23 de esfera I/C CBM externo e 22 2 min 1 STOP
EWO
61805 2RSL interno,(al ojamento da
Atuador Rotativo

bucha e do eixo) ROOT CAUSE

Kind of Maintenance
Verificar se há passagem

A de ar comprimido de um [m in ]
24 Gaxeta 100013165 GR-14 I CBM
l ado para outro dentro da
22 20 min 1 STOP
EWO
câmara do cil indro

• EWO Tallow
ROOT CAUSE
Verificar dentes da engrenagem Kind of Maintenance
(livr es de "pites" ou quebr as) e

A
Eixo de DESE NHO USINAGEM se seu engr enamento com a [m in ]
25
acionamento
HAC75004
EXT ERNA I CBM cr emalheira está dentro do 22 25 min 1 STOP
EWO
diâmetro primitivo. Verificar
folgas em suas extr emidades ROOT CAUSE
Kind of Maintenance
Verificar dentes da

A
[m in ]
26 Cremalheira I CBM cremalheira(l ivres de 22 25 min 1 STOP
EWO
"pites" ou quebras)
ROOT CAUSE

Mancais Pillar Results

Kind of Maintenance
Veri ficar pontos de fol ga

A
Braço de na arti culação e [m in ]
27
articulação
desenhar
I CBM
alinhamento do mesmo
22 15 min 3 STOP
EWO
em relação ao rolamento
ROOT CAUSE
Kind of Maintenance
Verificar fixação e se há

B
Mancal para [m in ]
28
rolamento
SY504 M
I/C CBM sinais de folaga no 22 5 min 3 STOP
EWO
aloj amento do rolamento
ROOT CAUSE

Verificar possíveis sinais Kind of Maintenance

de trinca, rachaduras ou

A
[m in ]

Next steps
29 Ventosas 1000125514 PG-03-50 I/C CBM desgaste excessivo nos 4 2 min STOP
EWO
l ábios de contato com as
caixas ROOT CAUSE
Kind of Maintenance
Verificar sinais de

B
Cilindro desgaste ou vazamento [m in ]
30
Pneumático
1000124793 PG-02-50 I/C TBM
de ar comprimido pelos
22 20 min 3 STOP
EWO

Hastes
reparos e conexões
ROOT CAUSE
Kind of Maintenance
Veri ficar se a passagem

A
Controlador de ar comprimido está [m in ]
31 1000116065 PG-03-36 I CBM 22 5 min 3 W orking

Servomotor
de fluxo sendo restringida quando EWO
Formaçãoo de caixas

fechado o mesmo

Correntes
ROOT CAUSE

Engrenagens
Kind of Maintenance

Mancais Empurradoras
Veri ficar se há folga em

A
[m in ]
32 Rótula 1000118158 DG -03-18 I CBM seu aloj amento e pino de 12 5 min 3 STOP
EWO

Eixos tracionadores
fixação
ROOT CAUSE

Rolamentos indexador
Kind of Maintenance

B
Tracionadoras
Verificar fixação e se há [m in ]

Sensores de
I/C 3

de tração
33 Fixação 1000124707 PG-02-54 CBM
sinais de desgaste/trinca
22 5 min W orking
EWO

de potes
ROOT CAUSE

Verificar possíveis sinais Kind of Maintenance

Mangueiras de folga na arti culação de

A
[m in ]
34 pneumáticas 1000187736 PB-01-10 I/C CBM movimentação de 22 15 min 3 STOP
EWO
PK6 desgaste na face de
contato com as caixas ROOT CAUSE

sincronismo
Kind of Maintenance
Verifi car possíveis

B
Filtro p/ trincas, sinai s de quebra [m in ]
35 vácuo I/C CBM
ou vasamento de ar
22 5 min 3 W orking
EWO
comprimido
ROOT CAUSE
Kind of Maintenance
Passagem interna de ar

A
Geradora de [m in ]
36 vácuo
1000125519 PG-04-05 I/C CBM comprimido livre de 22 10 min 3 STOP
EWO
impurezas
ROOT CAUSE
Kind of Maintenance
Verificar se sua resposta

A
Válvula [m in ]
37
solenóide
PG-05-43 I/C CBM após atuação da 22 5 min 3 W orking
EWO
solenóide é rápida
ROOT CAUSE

PLANNED MAINTENANCE
100%
OK 90%
80%
EX TRA
70%
ACTIVITY BREAKDOWN
NOT MAINTENANCE 60%

62
PLANNED 50%
40%
30%
PLANNED MAINTENANCE
20%

A 27 ###
B 10 ###
C 0 0%

37

VALINHOS JUN 2018

 STEP 4 EXPANSION - ICE

9000 AFTER
8000

7000

6000

5000
PILLAR SUMARY
4000
7030
3000
• Last Audit
2000
3200 Comments
1000 2230 2066 1835 1780 1760 1600
0 480 330 • Vision, Needs
Cilindro Cilindro Sistema de Servo motor e Conjunto Sensores Servo motor Braço de Resistência Relé contato
pneumático pneumático tração drive rosca de buchas, atuação da indexador regulagem de mecânico and Objectives
garras elevador potes indexador entrada rolamentos e rosca de separador de abertura da
empilhador mancais da entrada potes rosca • Route Map
rosca entrada
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
BEFORE Foi realizado a instalação de um micro que,
• Step 01
• Step 02
quando acionado, determina um tempo de 6
• Step 03
Troca da segundos para desarme da resistência após
• Step 04
resistência a cada selagem do filme, prolongando com isso a
• Step 05
2 meses, devido vida útil da mesma. (Out/2017)
• Step 06
deterioração da
mesma com Expansion
temperatura • ICE
elevada por muito
Cost Saving – R$2.211 • EWO Dove
tempo durante a micro R$ 75
• EWO Tallow
MO R$ 60
selagem do filme B/C = 17,3 MP-INFO Pillar Results
Total – R$135 Next steps
Tempo de reparo,
3 horas Saving
Custo da resistência Resistência R$ 1.506
R$251
TH1 e TH2 - Potencial Saving
MO R$ 840
R$4.422
Total – R$ 2.346 63
VALINHOS JUN 2018
 STEP 4 EXPANSION - ICE
AFTER
9000

8000

7000

6000

5000
PILLAR SUMARY
4000

3000
7030
6200 2017 2020 • Last Audit
5280
2000
3200 Comments
1000 August September October 2230
November December
1835 1780 January February March April May June July August September October November December
1600
0 480 330 • Vision, Needs
Cilindro Servo motor e Servo motor Cilindro Sistema de Conjunto Sensores Braço de Resistência Relé contato
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
pneumático drive rosca de indexador pneumático tração buchas,
1 2 3 4 5
atuação da regulagem de
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
mecânico and Objectives
garras entrada separador de elevador potes indexador rolamentos e rosca de abertura da
empilhador potes mancais da entrada rosca • Route Map
rosca entrada
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
Relé de estado Sólido (fabricante • Step 0
Gerfran), com um numero de • Step 01
BEFORE atuações superior a 1.000.000 • Step 02
(3 anos) • Step 03
Custo de R$240,00 • Step 04
Não foi realizado troca desde • Step 05
Nov/2017 • Step 06
Expansion
Rele da resistência
de soldagem do filme. Cost Saving – R$135 • ICE
• EWO Dove
Contato mecânico Relé estado sólido R$ 240
Fabricante “Finder” MO R$ 45 B/C = 1,4 • EWO Tallow
Pillar Results
Custo R$165,00 Total – R$285
Next steps
Troca a cada 6 meses Saving TH1 e TH2 - Potencial Saving
Relé mecânico R$ 330 R$270
MO R$90
Total – R$ 420
MP-INFO 64
VALINHOS JUN 2018
 STEP 4 EXPANSION - ICE

9000 B E F OR E
8000

7000

6000
Activity time= 22h 15min/year
5000
PILLAR SUMARY
800
4000
7030
3000 700
630 • Last Audit
2000
3200 600
Comments
1000 2230 2066 1835 1780 1760 1600
0 480 330
500
• Vision, Needs
Cilindro Cilindro Sistema de Servo motor e Conjunto Sensores Servo motor Braço de Resistência Relé contato
pneumático
garras
pneumático
elevador potes
tração
indexador
drive rosca de
entrada
buchas,
rolamentos e
atuação da
rosca de
indexador
separador de
regulagem de
abertura da
mecânico
400
320 310 and Objectives
empilhador mancais da entrada potes rosca 300
• Route Map
rosca entrada
200 160 • KPIs and KAIs
100 65 • Radar Chart
MACHINE LEDGER PAKMATIC 0
• Governance
Access to Disassembly Replacement Assembly Restart
component Pillar Methodology
• Step 0
• Step 01

AFTER • Step 02
• Step 03
• Step 04
Activity time=4h 20min / year • Step 05
700 • Step 06

600 Expansion

500
83% • ICE
• EWO Dove
400
• EWO Tallow
300
Pillar Results
200
120
Next steps
100 60
10 30 30
0
Access to Disassembly Replacement Assembly Restart
component

65
VALINHOS JUN 2018
 STEP 4 EXPANSION - ICE

PREVENTION
“TOP 10” PARETO OFCOSTS REDUCEDCOSTS
PREVENTION – STEP 4
– STEP 3

72% Spare costs R$22.311

R$6.176 PILLAR SUMARY

Labour costs R$2.680

R$435 • Last Audit
83% Comments
• Vision, Needs
TOTAL MAINTENANCE COST and Objectives

R$ 24.991 (Jul 2017 – Mai 2018) • Route Map

• KPIs and KAIs
9000
9000
• Radar Chart
8000
8000 • Governance
Pillar Methodology
7000
7000 STEP 4 • Step 0
6000
6000 COST • Step 01

5000
5000 260 REDUCTION • Step 02
• Step 03
4000
4000
73% • Step 04
7030 • Step 05
3000
3000
• Step 06
4300 TOTAL MAINTENANCE COST
2000
2000 260 Expansion
3200 R$6.611 (Jul 2017 – Mai 2018) • ICE
1000
1000 2230 2066 1835 1780 1760 60 45
1066 1600 • EWO Dove
00 0 0 0 0 0 0 480
135 330
240 • EWO Tallow
Cilindro
Cilindro Cilindro
Cilindro Sistemade
Sistema de Servomotor
Servo motoree Conjunto
Conjunto Sensores
Sensores Servomotor
Servo motor Braço de
Braço de Resistência
Resistência Relé contato
Relé contato Pillar Results
pneumático pneumático
pneumático pneumático tração
tração driverosca
drive roscade
de buchas,
buchas, atuaçãoda
atuação da indexador regulagem
indexador regulagem de
de mecânico
mecânico
Next steps
garras
garras elevadorpotes
elevador potes indexador
indexador entrada
entrada rolamentosee
rolamentos roscade
rosca de separadorde
separador de abertura
abertura da
da
empilhador
empilhador mancaisda
mancais da entrada
entrada potes
potes rosca
rosca
roscaentrada
rosca entrada

66
VALINHOS JUN 2018
 STEP 4 EXPANSION ICE - RESULTS

R$ 140.000,00
Custos - Pakmatic TH03 - Mai/17 a Mai/18
PILLAR SUMARY

• Last Audit
R$ 120.000,00
Comments
Started WCM Methodology • Vision, Needs
End of and Objectives
R$ 100.000,00 End of End of End of
Step 3 • Route Map
Step 0 Step 1 Step 2
• KPIs and KAIs
• Radar Chart
R$ 80.000,00
Total saving “Step 4” • Governance
Pillar Methodology
R$ 18.380
• Step 0
R$ 60.000,00 (73%) • Step 01
• Step 02
• Step 03
R$ 40.000,00 • Step 04
• Step 05
• Step 06
R$ 20.000,00 Expansion
• ICE
• EWO Dove
R$ - • EWO Tallow
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Fev Mar Abr Mai Jun Jul Ago Set Out Nov Dez Jan Fev Mar Abr Mai
Pillar Results
Next steps

Cost Planning Breakdown

67
VALINHOS JUN 2018
 PILLAR METHODOLOGY

EXPANSION
PILLAR SUMARY

Step7 • Last Audit

Comments
Step 6
Maintenance cost • Vision, Needs
management
Step 5 and Objectives
Build a predic- Establishment of • Route Map
Step 0 tive mainte- a planned • KPIs and KAIs
Step 4 Build a periodic nance system maintenance • Radar Chart
maintenance (trend system
Preliminary • Governance
system) management)
Activities Step 3 Countermeasures
Pillar Methodology
• Step 0
against weak
Step 2 points
• Step 01
Establishment of of the machine • Step 02

Step 1 maintenance and • Step 03

Reverse standards lengthened equip- • Step 04
deterioration ment life • Step 05
(breakdown analysis)
Elimination of forced • Step 06
deterioration Expansion
and prevention of • ICE
accelerated • EWO Dove
deterioration • EWO Tallow
Pillar Results
Next steps

REACTIVE PREVENTIVE PROACTIVE

68
VALINHOS JUN 2018
EXPANSION CD 5 ROUND

NEW EXPANSIONS EQUIPAMENTS

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

69
VALINHOS JUN 2018
EXPANSION CD 5 ROUND

NEW EXPANSIONS EQUIPAMENTS

PILLAR SUMARY

• Last Audit

47 •
Comments
Vision, Needs
New and Objectives

EQUIPAMENTS •
•
Route Map
KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01

14 AA •
•
Step 02
Step 03
• Step 04
• Step 05

3A • Step 06
Expansion

11
18 •
•
ICE
EWO Dove
EQUIPAMENTS • EWO Tallow

6B Pillar Results
Next steps

24 C 70
VALINHOS JUN 2018
EXPANSION

PILLAR SUMARY

• Last Audit
Comments

EWO • Vision, Needs

and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

71
VALINHOS JUN 2018
BREAKDOWN ANALYSIS DOVE

FENÔMENO
VAZAMENTO DE SOFI (PRODUTO) NA BOMBA DE
RECIRCULAÇÃO NA LINHA DO TROCADOR DE CALOR DO PILLAR SUMARY

REATOR JAC3 A UMA TEMPERATURA DE 245ºC, DURANTE A • Last Audit

FASE DE REAÇÃO, PODENDO ACARRETAR EM UM Comments
ACIDENTE DE ALTO POTÊNCIAL, SEM UMA TENDÊNCIA • Vision, Needs
DEFINIDA E INDEPENDENTE DA HABILIDADE DO and Objectives

MANUTENTOR E OPERADOR, COM UM TEMPO DE 24HRS • Route Map

• KPIs and KAIs
PARA RESTABELECIMENTO DAS CONDIÇÕES DE
• Radar Chart
OPERAÇÃO. • Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05

Espera para Manutenção • Step 06

Partida Expansion
manutenção Intervenção
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

72
VALINHOS JUN 2018
BREAKDOWN ANALYSIS DOVE

1. Dosagem de Ácido graxo PILLAR SUMARY

SOFI 245°C • Last Audit

1000mbar Comments
2. Dosagem de Isetionato • Vision, Needs
and Objectives
• Route Map
250m³/h 3. Recirculação de SOFI (resultante da • KPIs and KAIs
1,5minutos
adição de AWC+AIT-D) •
•
Radar Chart
Governance
Pillar Methodology

Fulgor 4. Ganho de temperatura atingindo • Step 0

• Step 01
>190°C 245°C • Step 02
• Step 03

PSM 5. impactos de qualidade depende da

• Step 04
• Step 05

fase em que parou o processo • Step 06

Expansion
• ICE

Acidente em Mannheim: Vazamento • EWO Dove

• EWO Tallow
Pillar Results
Next steps

73
VALINHOS JUN 2018
BREAKDOWN ANALYSIS DOVE

PILLAR SUMARY

• Last Audit
Comments
Selo mecânico Mola + anel de • Vision, Needs

vedação and Objectives

• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

74
VALINHOS JUN 2018
BREAKDOWN ANALYSIS DOVE

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives

Anel de vedação
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

75
VALINHOS JUN 2018
 BREAKDOWN ANALYSIS DOVE

PILLAR SUMARY

• Last Audit
Comments
Análise de ODS • Vision, Needs
and Objectives
• Route Map
ODS consiste na visualização do • KPIs and KAIs

ESPECÍFICADO movimento de uma estrutura, através • Radar Chart

ATUAL • Governance
5,4mm/s 3,5mm/s da medição de vibração, fornecendo Pillar Methodology

diagnóstico preciso para a resolução de •

•
Step 0
Step 01
problemas. • Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
ESPECIFICADO:M (r.€) = • EWO Dove

Xmax.K/F= 5,44 mm/s. • EWO Tallow

Pillar Results
Next steps

76
VALINHOS JUN 2018
BREAKDOWN ANALYSIS DOVE

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart

Laudo Técnico • Governance

Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

77
VALINHOS JUN 2018
BREAKDOWN ANALYSIS DOVE

PILLAR SUMARY

• Last Audit

Temperatura dos materiais Comments

• Vision, Needs
1500h and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
http://www.zrunek.at/uk/viton/competence/fluoroelastomer/properties/
temperature-resistance-zruelast-fpm-viton-fkm.html • Step 05
http://www.jjshort.com/Rubber-Properties.php
• Step 06
Limite 204ºC Expansion
• ICE
• EWO Dove
• EWO Tallow

Viton Pillar Results

Next steps

Trabalho
245ºC 78
VALINHOS JUN 2018
 BREAKDOWN ANALYSIS DOVE

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
Características: and Objectives

Maior raio e peso molecular • Route Map

• KPIs and KAIs
Não conduz eletricidade • Radar Chart

Não conduz calor • Governance

Pillar Methodology
Maior proteção sobre a • Step 0

camada de carbono • Step 01

• Step 02
• Step 03

CF3 F F F CF3 F • Step 04

F F F F F F • Step 05

H H H • Step 06
Expansion
• ICE
C C C C C C C C C C C C C C C • EWO Dove
• EWO Tallow

H H H Pillar Results
Next steps

F CF3 F F F F F CF3 F F F F

79
VALINHOS JUN 2018
 BREAKDOWN ANALYSIS DOVE

T= 204ºC Características
T= 245ºC
Taxa de
falha
Prematura Período vida útil operacional Desgaste
PILLAR SUMARY
http://www.gtweed.com/materials/fkm-vs-ffkm/
viton • Last Audit
Comments

Kalrez • Vision, Needs

and Objectives
• Route Map
T= 316ºC
• KPIs and KAIs
• Radar Chart
Tempo • Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

80
VALINHOS JUN 2018
BREAKDOWN ANALYSIS DOVE

M.O.C M.P
PILLAR SUMARY

• Last Audit
LABOR Comments
R$1.560 B/C SAVING • Vision, Needs
SPARE 3,78
R$4.000 R$5.560 •
and Objectives
Route Map
• KPIs and KAIs
• Radar Chart
6.000
VITON KALREZ • Governance
Pillar Methodology
• Step 0
4.500 • Step 01
• Step 02
• Step 03
• Step 04
3.000 • Step 05
• Step 06
2.000
Expansion
1.500 • ICE
• EWO Dove
• EWO Tallow

https://www.gallagherseals.com/blog/wp-content/uploads/2015/11/Kalrez-TCO-2-01.jpg Pillar Results

Next steps

81
VALINHOS JUN 2018
EXPANSION

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives

EWO •
•
Route Map
KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

82
VALINHOS JUN 2018
 5G – GEMJITSU + EWO
Ferramentas de análise

5W+1H
Princípio de Funcionamento
 Temperatura
do sabão entre
110 e 130°C

Camisa refrigerada Faca

para choque raspadora
Bico Ejetor de Sabão térmico entre o
sabão e a parede
interna do
Atomizador.

Nesse instante a
temperatura do
sabão cai para
50°/ 60°C
Bico Mancal
Eixo central injetor bi-partido
(tracionador da faca)
Silo Silo Silo Silo Silo Silo Silo Silo
1 2 3 4 5 6 7 8
 EWO
Ilustração – local da quebra rolamento

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map

Estrutura fixa • KPIs and KAIs

Rolamento Rolamento • Radar Chart

• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
Estrutura móvel
• EWO Dove
Eixo
• EWO Tallow
Pillar Results
Tripé de Fixação Secador Next steps

Parede do Atomizador
 EWO

1 – Por quê?

Quebra do rolamento Especificação incorreta do

inferior do eixo do rolamento
PILLAR SUMARY
atomizador Aplicação de força excessiva
• Last Audit

Rotação acima do recomendado Comments

• Vision, Needs

Aplicação de esforço excessivo and Objectives

• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps
 EWO

1 – Por quê?

Quebra do rolamento Especificação incorreta do

inferior do eixo do rolamento
PILLAR SUMARY
atomizador Aplicação de força excessiva
• Last Audit
Comments
Rotação acima do recomendado
• Vision, Needs

ROLAMENTO SKF 22210CC/W33 Aplicação de esforço excessivo and Objectives

• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
Carga total aplicado no rolamento 49.735 N • EWO Tallow
Carga total máxima suportada pelo rolamento 119.000 N Pillar Results
Next steps
Limite máximo de rotação 7.100 rpm
Rotação real 13 rpm
Vida nominal do rolamento 2,7 anos
Tempo de vida real 10 meses
 EWO

1 – Por quê? 2 – Por quê?

Quebra do rolamento Aplicação de esforço excessivo Pressão excessiva nas molas

inferior do eixo do
atomizador Acúmulo excessivo e não PILLAR SUMARY

uniforme de massa nas paredes • Last Audit

do atomizador Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps
 EWO

1 – Por quê? 2 – Por quê?

Quebra do rolamento Aplicação de esforço excessivo Pressão excessiva nas molas

inferior do eixo do
atomizador Acúmulo excessivo e não PILLAR SUMARY

uniforme de massa nas paredes • Last Audit

do atomizador Comments
• Vision, Needs
Condição Ideal Condição Real and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps
 EWO

1 – Por quê? 2 – Por quê?

Quebra do rolamento Aplicação de esforço excessivo Acúmulo excessivo e não

inferior do eixo do uniforme de massa nas paredes
atomizador do atomizador PILLAR SUMARY

• Last Audit
Comments
3 – Por quê? • Vision, Needs
and Objectives
Variação nos parâmetros da • Route Map
massa • KPIs and KAIs
• Radar Chart
Ausência de troca térmica • Governance

necessária devido à deficiência Pillar Methodology

na refrigeração • Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps
 EWO

1 – Por quê? 2 – Por quê?

Quebra do rolamento Aplicação de esforço excessivo Acúmulo excessivo e não

inferior do eixo do uniforme de massa nas paredes
atomizador do atomizador PILLAR SUMARY

• Last Audit
Comments
3 – Por quê? • Vision, Needs
and Objectives
Variação nos parâmetros da • Route Map
massa • KPIs and KAIs
• Radar Chart
Ausência de troca térmica • Governance

necessária devido à deficiência Pillar Methodology

na refrigeração • Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps
 EWO

1 – Por quê? 2 – Por quê?

Quebra do rolamento Aplicação de esforço excessivo Acúmulo excessivo e não

inferior do eixo do uniforme de massa nas paredes
atomizador do atomizador PILLAR SUMARY

• Last Audit
Comments
3 – Por quê?
Saída de Água • Vision, Needs
and Objectives
Variação nos parâmetros da • Route Map
massa • KPIs and KAIs
• Radar Chart
Ausência de troca térmica • Governance

necessária devido à deficiência Pillar Methodology

na refrigeração • Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
Entrada de
• ICE
Água
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

Endoscopia do sistema de refrigeração

da camisa do atomizador
 EWO

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs

Endoscopia and Objectives

Camisa superior • Route Map

• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
Endoscopia
Camisa inferior • EWO Dove
• EWO Tallow
Pillar Results
Next steps
 EWO

1 – Por quê? 2 – Por quê?

Quebra do rolamento Aplicação de esforço excessivo Acúmulo excessivo e não

inferior do eixo do uniforme de massa nas paredes
atomizador do atomizador PILLAR SUMARY

• Last Audit
Saída de Água Comments
3 – Por quê? • Vision, Needs
and Objectives
Variação nos parâmetros da • Route Map
massa • KPIs and KAIs
• Radar Chart
Ausência de troca térmica • Governance

necessária devido à deficiência Pillar Methodology

na refrigeração • Step 0
Ponto máximo de alcance • Step 01

2/3 do atomizador da • Step 02

• Step 03
água de refrigeração. • Step 04
• Step 05
• Step 06
Expansion

Entrada de • ICE

Água • EWO Dove

• EWO Tallow
Pillar Results
Next steps
 EWO

1 – Por quê? 2 – Por quê?

Quebra do rolamento Aplicação de esforço excessivo Acúmulo excessivo e não

inferior do eixo do uniforme de massa nas paredes
atomizador do atomizador PILLAR SUMARY

• Last Audit
Comments
3 – Por quê? • Vision, Needs
and Objectives
Ausência de troca térmica • Route Map
necessária devido à deficiência • KPIs and KAIs
na refrigeração • Radar Chart
Válvula aberta • Governance

4 – Por quê? Pillar Methodology

• Step 0

Falha na manobra da válvula de • Step 01

entrada de água • Step 02

• Step 03
• Step 04
Baixa vazão de água para os
• Step 05
secadores • Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps
 EWO

1 – Por quê? 2 – Por quê?

Quebra do rolamento Aplicação de esforço excessivo Acúmulo excessivo e não

inferior do eixo do uniforme de massa nas paredes
atomizador do atomizador PILLAR SUMARY

• Last Audit
Comments
3 – Por quê? • Vision, Needs
and Objectives
Ausência de troca térmica
Válvula aberta • Route Map
necessária devido à deficiência • KPIs and KAIs
na refrigeração • Radar Chart
• Governance

4 – Por quê? Pillar Methodology

• Step 0

Baixa vazão de água para os • Step 01

• Step 02
secadores • Step 03
• Step 04
5 – Por quê? • Step 05
• Step 06
Falha na manobra de envio de Expansion
água para os secadores • ICE
• EWO Dove
Dimensionamento incorreto da 𝐶 (𝑐𝑎𝑙 ⁄𝑔. °𝐶) = 0,003 𝐻 𝑂 % + 0,002 𝑇°𝐶 + 273 − 0,15 • EWO Tallow

bomba de envio 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑 𝑃𝑜𝑤𝑒𝑟 (𝐾𝑤) × 0,65 × 857 Pillar Results

𝑚̇ (𝑘𝑔⁄ℎ) = Next steps
∆𝑇 (°𝐶)
𝑚̇ = 10 𝑡𝑜𝑛⁄ℎ
∆T = 2 °𝐶 → 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑 𝑃𝑜𝑤𝑒𝑟 = 194 𝐾𝑤
𝑽𝒂𝒛ã𝒐 𝒅𝒆 á𝒈𝒖𝒂 𝒓𝒆𝒒𝒖𝒆𝒓𝒊𝒅𝒂 𝒏𝒐𝒔 𝒔𝒆𝒄𝒂𝒅𝒐𝒓𝒆𝒔: 𝒎̇𝑯𝟐 𝑶 = 𝟓𝟒 𝒎𝟑 ⁄𝒉
 EWO
P&D – SISTEMA DE REFRIGERAÇÃO FÁBRIFCA DE SABONETES

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps
 EWO
P&D – SISTEMA DE REFRIGERAÇÃO FÁBRIFCA DE SABONETES

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps
 EWO

1 – Por quê? 2 – Por quê?

Quebra do rolamento Aplicação de esforço excessivo Acúmulo excessivo e não

inferior do eixo do uniforme de massa nas paredes
atomizador do atomizador PILLAR SUMARY

• Last Audit
Comments
3 – Por quê? • Vision, Needs
and Objectives
Ausência de troca térmica • Route Map
necessária devido à deficiência • KPIs and KAIs
na refrigeração • Radar Chart
• Governance

4 – Por quê? Pillar Methodology

• Step 0
𝐶 (𝑐𝑎𝑙 ⁄𝑔. °𝐶) = 0,003 𝐻 𝑂 % + 0,002 𝑇°𝐶 + 273 − 0,15
Baixa vazão de água para os 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑 𝑃𝑜𝑤𝑒𝑟 (𝐾𝑤) × 0,65 × 857
• Step 01
• Step 02
secadores 𝑚̇ (𝑘𝑔⁄ℎ) =
∆𝑇 (°𝐶) • Step 03
𝑚̇ = 10 𝑡𝑜𝑛⁄ℎ • Step 04
5 – Por quê? • Step 05
∆T = 2 °𝐶 → 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑 𝑃𝑜𝑤𝑒𝑟 = 194 𝐾𝑤
• Step 06
Falha na manobra de envio de 𝑽𝒂𝒛ã𝒐 𝒅𝒆 á𝒈𝒖𝒂 𝒓𝒆𝒒𝒖𝒆𝒓𝒊𝒅𝒂 𝒏𝒐𝒔 𝒔𝒆𝒄𝒂𝒅𝒐𝒓𝒆𝒔: 𝒎̇𝑯𝟐 𝑶 = 𝟓𝟒 𝒎𝟑 ⁄𝒉
Expansion
água para os secadores • ICE
• EWO Dove
Dimensionamento incorreto da • EWO Tallow

bomba de envio Pillar Results

Next steps
 EWO
P&D – SISTEMA DE REFRIGERAÇÃO FÁBRIFCA DE SABONETES

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps
 EWO
P&D – SISTEMA DE REFRIGERAÇÃO FÁBRIFCA DE SABONETES

PILLAR SUMARY

Ponto de picagem • Last Audit

para tomada de Comments
pressão - PR203 • Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps
 EWO

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs

Endoscopia Antes and Objectives

Camisa superior • Route Map

• KPIs and KAIs
Após picagem • Radar Chart
para tomada de • Governance
pressão - PR203 Depois
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
Endoscopia
Camisa inferior • EWO Dove
• EWO Tallow
Pillar Results
Next steps
 Análise do Rolamento
ROLAMENTO SKF 22210CC/W33

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps
 Substituição do Rolamento
Medida de contenção vibração

PILLAR SUMARY

• Last Audit
Comments

$ 1.955,00 $ 335,00 • Vision, Needs

and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
ROLAMENTO SKF 22210CC/W33 • Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion

PLANO quinzenal DE INSPEÇÃO • ICE

• EWO Dove
• EWO Tallow
Pillar Results
Next steps

 Alteração Item na machine ledger

 Padronização
SOP’s e Smp’s para inspeção dos pontos críticos

SMP (MAINTENANCE)

PILLAR SUMARY

Amarração dos pontos via calendário AM • Last Audit

Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance
Pillar Methodology
• Step 0
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps
 PILLAR RESULTS
PILLAR SUMARY

Step7 • Last Audit

Comments
Step 6
Maintenance cost • Vision, Needs
management
Step 5 and Objectives
Build a predic- Establishment of • Route Map
Step 0 tive mainte- a planned • KPIs and KAIs
Step 4 Build a periodic nance system maintenance • Radar Chart
maintenance (trend system
Preliminary • Governance
system) management)
Activities Step 3 Countermeasures
Pillar Methodology
• Step 0
against weak points
Step 2 of the machine and
• Step 01
Establishment of lengthened equip- • Step 02

Step 1 maintenance ment life • Step 03

standards • Step 04
• Step 05
Reverse
Elimination of forced deterioration • Step 06
deterioration (breakdown analysis) Expansion
and prevention of • ICE
accelerated • EWO Dove
deterioration • EWO Tallow
Pillar Results
Next steps

REACTIVE PREVENTIVE PROACTIVE

108
VALINHOS JUN 2018
COST REDUCED

PILLAR SUMARY

• Last Audit
Comments
• Vision, Needs
and Objectives
• Route Map
• KPIs and KAIs
• Radar Chart
• Governance

Reduction
Reduction
Pillar Methodology
• Step 0
29%
k€ 832
• Step 01
• Step 02
• Step 03
• Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

109
VALINHOS JUN 2018
 PILLAR RESULTS

Breakdown Expansion Breakdown all equipments

400 2000

Reduction
PILLAR SUMARY
350 1800
Reduction 1600
65%
300 • Last Audit
1400
45% Comments
Breakdown

250

Breakdown
1200
• Vision, Needs
200 1000
372 Trend 1852 Trend and Objectives
800 1700
150 294
BD BD • Route Map
600
100 • KPIs and KAIs
400
50 99 200 540 • Radar Chart
0 0 • Governance
16' 17' 18' 16' 17' 18' Pillar Methodology
Year Year • Step 0
• Step 01
• Step 02
MTTR MTBF • Step 03
80000 140 • Step 04

70000 • Step 05

60000
Reduction 120
Increase • Step 06

64% 54%
100 Expansion
MTTR (Min)

50000
80 • ICE
MTBF

40000
72879 Trend • EWO Dove
60 Trend
30000 55311 • EWO Tallow
MTTR MTBF
20000 40 Pillar Results

10000 20 Next steps

13585
0 0
16' 17' 18' 16' 17' 18'
Year Year
110
VALINHOS JUN 2018
 NEXT STEPS
PILLAR SUMARY

Step7 • Last Audit

Comments
Step 6
Maintenance cost • Vision, Needs
management
Step 5 and Objectives
Build a predic- Establishment of • Route Map
Step 0 tive mainte- a planned • KPIs and KAIs
Step 4 Build a periodic nance system maintenance • Radar Chart
maintenance (trend system
Preliminary • Governance
system) management)
Activities Step 3 Countermeasures
Pillar Methodology
• Step 0
against weak points
Step 2 of the machine and
• Step 01
Establishment of lengthened equip- • Step 02

Step 1 maintenance ment life • Step 03

standards • Step 04
• Step 05
Reverse
Elimination of forced deterioration • Step 06
deterioration (breakdown analysis) Expansion
and prevention of • ICE
accelerated • EWO Dove
deterioration • EWO Tallow
Pillar Results
Next steps

REACTIVE PREVENTIVE PROACTIVE

111
VALINHOS JUN 2018
 NEXT STEPS

PILLAR SUMARY

 Continue in step 3 in the expansion machines to ensure zero breakdown • Last Audit
Comments

due to lack of maintenance, consequently advance to step 4; • Vision, Needs

and Objectives
• Route Map

 Start step 5 in Pakmatic TH3 and continue in step 6 in MM; •

•
KPIs and KAIs
Radar Chart
• Governance
Pillar Methodology
 Accelerate in Expansion to 47 machines; • Step 0
• Step 01
• Step 02

 Implement actions from this audit •

•
Step 03
Step 04
• Step 05
• Step 06
Expansion
• ICE
• EWO Dove
• EWO Tallow
Pillar Results
Next steps

112
VALINHOS JUN 2018
THANK YOU
OBRIGADO

113
VALINHOS JUN 2018