Traditional Factory Management vs FactOS

Problem Statement - Breakdown Management

Today breakdowns happen in large numbers at factories due to the non-availability of data required for root cause analysis and preventive maintenance.

• In a large factory setup, the breakdown happens almost every hour.?
• There is zero traceability and accountability.
• Breakdowns are not realized in real-time. (due to lack of right communication and action)

Existing Traditional Management

What does a typical breakdown workflow look like in a factory?

1. Often breakdowns are not reported promptly by the operators to the Production supervisors resulting in delayed communication.
2. The production team informs the maintenance teams about the breakdown informing them about the asset, the possible cause, and the resolution priority.
3. This communication happens either over a phone call, an email, or on a physical check sheet.
4. The breakdown is then recorded by the maintenance team and is shared with the designated personnel for resolution.
5. The assigned user takes his/her own time to find the asset, understands the problem, and rectifies the issue because at times the information and priority are not communicated properly.
6. The maintenance personnel resolve the issue by changing a few spare parts that go untracked.
7. The personnel post resolution informs the production supervisor who in turn instructs the machine operator to start production.
8. All of this information is either not captured at all or is not captured in detail.

This results in inaccurate root cause analysis resulting in frequent breakdowns.

Communication is a challenge and hence breakdowns today take 3x more time than they should. Furthermore, there is no accountability between teams.

Effects

• Inaccurate root cause analysis
• Blame games between various stakeholders
• Huge production losses
• Zero breakdown traceability

Breakdown Management With FactOS (Factory Operation System)

1. The breakdown management module on the FactOS App in real time informs the supervisor of a possible asset breakdown on the shop floor.
2. The Shift Supervisor / Machine Operator instantly raises a ticket with the possible cause and the priority using a simple digital check sheet.?
3. The maintenance team gets an instant alert on their dashboard with details of the asset and the possible cause.?
4. The dashboard lists all the breakdowns according to their priorities for immediate action.
5. Utilization of spare parts is tracked during a breakdown resolution for root cause analysis.?
6. The maintenance personnel post testing and validation resolves the ticket.
7. An instant alert is shared with the operator and the production supervisor of breakdown closure.?
8. Operator starts production.

Effects

• Streamlined communication.
• Improved Accountability.
• Availability of accurate data for root cause analysis.
• Ready reports with MTTA and MTTR for traceability.
• Optimized preventive maintenance schedules.