Machines can't go down at all...... Management wants statement

[BradM]

No, no, no. Do not do this. Sounds like a good way to lose your fingers or maybe your life.

Is Management aware you are doing this?

If Management is aware, and don't care, you need to find a new job, ASAP.

I don't think it can be stressed enough what Mike S. said here. No production run is worth an employee getting injured.

 

[BradM]

Every machine has a reliability rate based on age, usage, PM, frequency of PM, etc. Too... there are just some things that happen in life that cause an issue.

I know you need a job and have worked very hard at this one. However... I'm not sure this job is worth it. To ask someone a (pardon the word) ridiculous question like that shows an appalling lack of understanding with respect to production factors, and an incredibly insensitive approach of wanting to blame missing production on you.

First, I would tell them, in writing, there is no definitive way to state 100% operation on these machines due to random variation.

Second, if they haven't done it already, they need to plan out their production runs carefully to allow for maximum run time between changes.

Finally, whether it's a human or a machine, you can't run a resource non-stop. They need to do some better capacity planning and purchase more machines, or be more realistic with customers and not make promises they can't keep.

 

[Claes Gefvenberg]

I had to bypass the security door and goes inside the machine during running to do the lubrication, cleaning and screw checking.

No, please do not do that! Surely, the door is there for a reason, and that is to keep you in one piece. Even considering the unreasonable requirement I think nobody will thank you for getting hurt and maybe rendered incapable of working, or even worse.

If the machines need to be worked on while in use, the safety barriers should be redesigned to allow for doing so in a safe way, but please do never disregard the safety precautions in use.

 

[Edward Reesor]

I had to bypass the security door and goes inside the machine during running to do the lubrication, cleaning and screw checking.

Good sir,

By now you have read the concerns that the other contributors have for your safety and I will assume that you have weighed the risk on personal injury and have deemed that it is an "acceptable risk". I will not echo the concern of others for I feel that my concern for your safety will also not be heeded...

So let me put the message in another perspective: Bypassing the security door and tightening screws during the operation of the device has a greater risk of causing mechanical failure in the event that either you or your tools (oil can, screwdriver or loose screw) fall into the working mechanism and become embedded into the machine. This would create a much greater MTTR than performing proper maintenance and would carry a much higher cost of repair.

Also, my business involves critical care equipment to EMS and ambulance services around the world, and I have a very close relationship with medical personal in many countries. As such, I have seen the results of scenes where maintenance crews have been seriously harmed by taking short cuts. Regardless of your concern for personal safety, I can tell you that the manufacturing process was shut down for a considerably longer period of time than if routine maintenance was performed properly in the first place.

 

[gpainter]

No, you can not make the assurance. Too many unknowns. Do you have a good PM in place and is it done, any predictive in place are you protected against power supply interruption, do you have back -up power, disaster planning, etc.

 

[bigqman]

Yes be Safe above all. Hopefully you can educate your management:
Running "non-stop" is probably not optimal. Why? Because there are other losses that can occur besides just equipment breakdown. Reduced Speed loss, process defects loss, increased start-up rejects, an increase in small or unplanned stops - these losses need to be accounted for in realizing best productivity.

 

[LumaraC]

Every machine has a reliability rate based on age, usage, PM, frequency of PM, etc. Too... there are just some things that happen in life that cause an issue.

I know you need a job and have worked very hard at this one. However... I'm not sure this job is worth it. To ask someone a (pardon the word) ridiculous question like that shows an appalling lack of understanding with respect to production factors, and an incredibly insensitive approach of wanting to blame missing production on you.

First, I would tell them, in writing, there is no definitive way to state 100% operation on these machines due to random variation.

Second, if they haven't done it already, they need to plan out their production runs carefully to allow for maximum run time between changes.

Finally, whether it's a human or a machine, you can't run a resource non-stop. They need to do some better capacity planning and purchase more machines, or be more realistic with customers and not make promises they can't keep.

Hi Sir,

No. 1
I have emphasized in meeting and in writing that there is no way to machine running without stop but...

No. 2
About the planning, in beginning we had very stable and more room for machine to breath.
From machine running 5days/week to 6days/week then to 6.5days/week (6.5days/week running production is the limit I have set for all my machine as I would like to have 0.5day/week to do the PM & etc) then it got until 7days/week.

No. 3
Agreed, we need more machine to expand the capacity.
It is still under disscusion but we have been like this 7days/week since Mid 2016.


Thank you for your reply Sir.

 

[LumaraC]

Good sir,

By now you have read the concerns that the other contributors have for your safety and I will assume that you have weighed the risk on personal injury and have deemed that it is an "acceptable risk". I will not echo the concern of others for I feel that my concern for your safety will also not be heeded...

So let me put the message in another perspective: Bypassing the security door and tightening screws during the operation of the device has a greater risk of causing mechanical failure in the event that either you or your tools (oil can, screwdriver or loose screw) fall into the working mechanism and become embedded into the machine. This would create a much greater MTTR than performing proper maintenance and would carry a much higher cost of repair.

Also, my business involves critical care equipment to EMS and ambulance services around the world, and I have a very close relationship with medical personal in many countries. As such, I have seen the results of scenes where maintenance crews have been seriously harmed by taking short cuts. Regardless of your concern for personal safety, I can tell you that the manufacturing process was shut down for a considerably longer period of time than if routine maintenance was performed properly in the first place.

No, please do not do that! Surely, the door is there for a reason, and that is to keep you in one piece. Even considering the unreasonable requirement I think nobody will thank you for getting hurt and maybe rendered incapable of working, or even worse.

If the machines need to be worked on while in use, the safety barriers should be redesigned to allow for doing so in a safe way, but please do never disregard the safety precautions in use.

Hi Sirs,

Yes, you are right.
today I have check with our Safety Officer regarding Accident caused by machines (whether by follow the rule/bypass & shortcut)
If the Government Agency found about it, they will compound, penalty and the manufacturing licenses will be terminated.

Thank you for highlight this to me, I will be extra caution next time while handling the machine.
I understood the weight but I can't let the machine down because of small thing like forget to lubricate/thighten the screw..because in same time I try to reduce my working hours as I have comimtment at home, I can't be always On-Call whenever the machine down at middle of night.

But I will discuss this more with our Safety Officer
Maybe this is my oppurtunity, as the machine need to stop whenver we do small servicing or not the machine will not last longer/the company have a risk to get compound whenever there have accident caused by someone risk themself to do the servicing during machine running.


Thank you Sirs for your reply.

 

[LumaraC]

Yes, I know this is sound not good and bad...

but I try to do my full best before I can put the excuse to the management.
I'm not willing to accept that management loses orders/productivity while I'm only give 80% of work effiency.

I try to learn more in order to be more efficient so that all the machines are also in their top efficiency condition. There still have room to improve, I still need to have more experience in handling machinaries.
What I saw myself right now is that, I always few steps backward when taking action.
I don't just repair the machine but also to improve it so that it will not happen in future.

That is why I really gratefull when Elsmar's Member share their experience/knowledge,
it really help me.

*by " I " is mean myself and my team.

 

[Edward Reesor]

I try to learn more in order to be more efficient so that all the machines are also in their top efficiency condition.

A famous quote (attributed to Abraham Lincoln) might apply in your situation, "If I had 8 hours to chop down a tree, I would spend 6 of those hours sharpening my axe."