Apollo Vredestein Environment

Tools

Technician

Actions

1.1 While the machine is running, not all tasks can be executed. Therefore, the machine is stopped during the PIPO’s.

1.2 A technician has to walk a two to four times to the warehouse daily, which is around 250 meters from the work place.

1.3 The technician walks a significant amount of time to the PC’s on a day.

1.4 External companies are hired in for exceptional and expert maintenance tasks.

1.5 Machines are highly dependent on each other. For example, a machine knows at what times it can expect certain products of other machines. When a machine is stuck and not producing while other machines are waiting for the products, it can become costly for the company quickly. This follows a “Just-In-Time” management.

2.1 The technicians uses its own senses very frequently to obtain information (sight, hearing, feeling - e.g. temperature).

2.2 Measure devices, wrenches, screwdrivers, hammers, saws, tape and cable ties are tools that technicians use.

2.3 Like the car technicians, every technician owns its own tool box on wheels. 2.4 While performing a maintenance task, the technician always uses its both hands.

3.1 A technician can loose a significant amount of time on unscheduled work for other technicians, when additional help or knowledge is necessary.

3.2 Most technicians tell that overall there is a shortage to the amount of available technicians in order to complete all maintenance work in time.

3.3 A technician tells that it is a possibility that operators will perform a number of easy technician tasks in the future, in order to reduce the workload for the technicians.

4.1 PIPO’s are executed on a frequent basis, varying between once every two weeks to once every month.

4.2 When ordering machine parts, the delivery of the parts can take between two and five weeks. 4.3 With decisions that involves orders with large amounts of money, the technicians communicate with

their supervisor in order to make a decision.

4.4 Before and after a PIPO, one technician and one operator should fill in a checklist. Especially the end-time of the PIPO is important to the maintenance manager.

4.5 The technician mentions that it is very important to think about safety and safety-rules before and during the work.

Learning

Information sources

Technology

4.6 After the PIPO, the expert-technician fills in a document on Excel in which all executed tasks are reported together with a small description or particularities. This will be send to the supervisor.

5.1 At least one specialist per machine that has deep knowledge about the workings of the machine, both electrical and mechanical, and about the history of the machine, is very important for repairing quickly.

5.2 Knowledge about machines is obtained by doing, asking colleagues and using documentation.

6.1 SAP: since it is hard for the organization to make changes in SAP, technicians decide on their own which tasks they will perform and which not. Hereby, they give priority to disruptions of machines. 6.2 Logbook machine: since operators have to fill in the important events to the machine in many

different forms, they tend to fill in no or very few information in this document.

6.3 Intranet: technicians complain about the disability of Intranet to write to SAP. It is only possible to read data from SAP.

6.4 DMS: technician suggest to include more images to visualize where parts are placed within a machine.

6.5 DMS: it is possible for the technician to adjust and add objects to this system.

6.6 DMS: very few technicians create work instructions, which documents how a certain task should be executed including pictures, drawings and reference links to other pages in DMS.

6.7 Machine: the machine can display a lot of information and data from sensors to the operators and technicians, including error messages and raw data.

6.8 SAP: one technician mentions it would be great to have a ‘status’ of every maintenance task, including e.g. that anyone is working on the task, or that the task should wait for any reason. 6.9 SAP: technicians complain about the loading time of SAP: it is always time consuming. Where

some has to wait for a couple of minutes to load a list, others are waiting for 20 minutes. Reading as well as writing requires time.

6.10 SAP: includes mistakes in which Monday is considered as the last day of the week, resulting in wrong lists for the supervisor.

6.11 When technicians need additional information when executing a maintenance task, they ask over the phone or print out documents like schemes and work instructions from DMS.

6.12 In most cases DMS contains full information. However, it occurs that drawings, documents and parts are missing in the system.

6.13 Machine displays: the machine can generate alerts with three types (notification, warning and error). Also a history of all alerts is available on this screen.

6.14 Logging of a sensor can be used as information source to find the cause of an issue. 6.15 Additional information for an electrician during its job mainly are the electrical schemes.

6.16 Machine displays: the machine knows very specifically what happens to the machine (e.g. which emergency stop is pressed).

7.1 The technician mentions that there is a large amount of passwords for all systems, which are only saved on two of the five PC’s.

Communication and planning