In manufacturing, safety is everybody's responsibility. Health and safety incidents and workplace injuries straight affect workers, spirits, productivity, company track record, and the bottom line.
" All plants state safety is in their top priority," state Ron Moore, a worldwide renowned professional on manufacturing quality. "It's a good thing to say, but generally it isn't supported by actions." Moore's research clearly shows that actions that enhance dependability really improve safety too.
Reliable Machines are Safer.
Every human-machine interaction can possibly trigger an injury. But there's still limited to no awareness of the relation between the dependability of machines and the health and safety of the individuals that work on them. Moore actually collected data that clearly shows the relationship between employee safety and machine dependability. His work shows worker injury accident rates vs Overall Equipment Effectiveness "OEE" and Asset Utilization "AU" in manufacturing centers.
As facilities enhance their "OEE" and "AU", their worker injury rate decreases, and according to him, this trend corresponds throughout all manufacturing industries from food and beverage to oil and gas.
Reactive Works Causes Injuries.
Moore's research also reveals that manufacturing facilities with high reactive work orders "WO" have more injuries When maintenance groups do unexpected repair in action to a failure or a breakdown, they work under tremendous pressure from the production group to bring up the machines and are most likely to take faster ways.
A rushed repair work order is not as safe or efficient as a "WO" done during a prepared shutdown. As Moore mentions, no job is so immediate that it can not be done securely. Manufacturers need to do everything to minimize the variety of human and machine interactions overall in order to restrict the safety risk to their maintenance team. Also, Moore's work shows that lowering reactive maintenance WO increases "OEE" and "AU" while cutting maintenance expenses.
The most reliable method to prevent reactive work is to get rid of unplanned failures and breakdowns. Ideally, every repair work should be arranged and prepared ahead of time-based on determined flaws, and assigned to properly proficient maintenance workers that have all of the essential parts and tools easily offered.
Focus On Reliability to Improve Safety.
Maintenance departments often bear an unjust quantity of the blame for machine breakdowns. According Moore's gathered data, almost 2/3 of devices failures are not brought on by maintenance practices, however by problems upstream. "Companies do not seem to understand the entire series of things that take place before downtime occurs," he says.
Reliability needs to shift the focus from immediate repair work and the associated maintenance expenses, to the root causes of a failure event. All the reliability Process consists of how companies design, buy, set up, run and keep their equipment. Utilizing this process companies can identify and detect where machine failures come from and improve machine dependability throughout the company.
Some questions to ask yourself consist of: Did anything in the system design helped in creating this issue? Was the right devices acquired? How was the parts or machine stored and was it installed or fixed effectively? Was the machine operated carefully? Is the maintenance team trained to determine and prevent these issues?
Senior manufacturing leaders can show their commitment to their worker safety by taking reliability programs as seriously as safety programs.
Healthy Machines Keep Workers Safe.
Much better safety training, checklists, standard word instructions, safety tools make human-machine interactions much safer, but decreasing the need for your workers to interact with harmful machines in the very first place is the supreme goal.
Machine Health uses IoT and AI to predict and avoid machine failures. It eliminates unneeded maintenance tasks, cuts the variety of human-machine interactions, moves more of the maintenance group's work from reactive to proactive mode, and improves OEE.
Healthy machines are safer and more reliable. As manufacturers improve their Machine Health, they will also ensure employee safety. A reliable plant genuinely is a safer plant.
コメント