Frito talks CMMS
The sixth annual Packaging Automation Forum was held April 26 in Chicago, and among the speakers was Ed Michel, who manages the Computerized Maintenance Management system at Frito-Lay.
"One of the key learnings we've had is that it requires three things—process, people, and technology—to be good at this," Michel told his audience. "Simply throwing technology at it is not going to work."
Other highlights of Michel's presentation:
• For many years we viewed reliability as a cost at our company. But when we took a look at reliability through a different lens, we realized that in fact it's a great enabler and a means of capital avoidance. After all, operating unreliably requires more equipment, and more equipment takes capital expenditures.
• For too long reliability at each of our sites was dependent on the leadership at that site. So we basically had 36 independent processes and systems for reliability. That meant many "best" ways to execute the same activity. It led to confusion, duplication of efforts, and inconsistent performance.
• Since starting this journey in 2002 we have reduced downtime by 50%.
• Improving reliability is impossible if you don't document what you do. In the old days, documentation was kept in a big book with all the equipment listed in it. You'd fill it out and hand it to your manager, and the manager would give it to administration, and some weeks later it made its way to those responsible for improving reliability. This was not working. So now, through the Avantis CMMS solution from Invensys Operations Management, we have an electronic interface on every one of our terminals on our plant floors. Anybody in the building can walk up to a terminal and in 15 seconds enter in a work request or emergency work order for a piece of equipment. You don't need anything other than this Avantis interface. It's the technology part of the overall project.
• Another discovery along the way was that time-based Preventive Maintenance is inferior to use-based. With our CMMS solution, we can easily and automatically keep track of machine cycles. If a machine cycles a million and a half times in ten days, it may need PM every ten days. Other machines may not need it so frequently because they're not cycling as frequently. By being able to automatically track machine cycles, we're leveraging technology to know when PM is needed.
• We're moving now to Autonomous Maintenance. It's a matter of engaging everyone at the plant in the process of maintaining equipment, not just the Maintenance Department.
• You can't simply throw a software solution at a problem like downtime and expect to make any progress if you don't have a process to leverage the technology and people to bring it all together. The CMMS software solutions, after all, are pretty much the same in terms of their functionality. They help you automatically keep score. But the only way to improve the score that's being kept is to engage people in a tech-enabled process.