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CLT ver1.00
Mission
 80% OPE (Overall Plant
Efficiency).
 90% OEE (Overall Equipment
effectiveness).
 100% in delivering the goods
to costumers.
 Work in accident free
environment.
 Develop Multi-skilled and
flexible workers.
 Higher confidence level
among the employees
 Work place cleans, neat and
attractive.
 Favourable change in the
attitude of the operators.
 Achieve goals by working as
team.
 Share knowledge and
experience.
Strategic Goal
By implementing CLT (A maintenance tool) in the
manufacturing industries.
To reduce manufacturing cost
To Improve the OEE (Overall Equipment Efficiency
To minimize the manufacturing losses (Downtime loss, Speed loss
and Quality loss)
What is CLT ?
CLT is a basic medical science for machine in manufacturing. It is a
simple tool to keep the manufacturing plant in a healthy state which
can deliver at maximum efficiency.
C: Cleaning – Eliminating dirt, dust, exposing all abnormalities,
correcting minor flaws and establishing basic equipment condition.
L: Lubricating – Reduce the Friction, Heat Generation,
Overloading.
T: Tightening - It only takes one loose bolt to start a chain of
reaction of wear and vibration, as a machine vibrates slightly, other
bolts work loose, vibration feeds on vibration, the equipment starts
to rattle and shake, tiny cracks widen into gaping splits, parts
become damaged and the result is major breakdown.
Introduction of CLT
 Manufacturing
 Maintenance
 Operations
 Design Engineering
 Plant and Site Management
 Project Engineering
 Engineering
 Inventory and Stores
In order to properly understand the impact of CLT, it is necessary to
establish a definition. CLT (Cleaning/Lubricating/Tightening) is
maintenance activities that are productive and implemented by all
employees. CLT involves everyone in the organization from
operators to senior management in equipment improvement. It
encompasses all departments including:
Cost-Benefit Strategic Goals
 Productivity
100-200% increases
50-100% increase in rates of
operation.
500% decrease in breakdowns
 Quality
100% decrease in defects.
50% decrease in client claims
 Costs
50% decrease in labour costs.
30% decrease in maintenance
costs
30% decrease in energy costs
 Inventory
50% reduction on inventory
levels.
100% increase in inventory
turns
 Safety
Elimination of environmental
and safety violations
 Morale
200% increase in suggestions
Increased participation of
employees in small group
meetings
CLT Philosophy
Old Attitude
“I operate, you fix.”
“I fix, you design.”
“I design, you operate.”
CLT Attitude
“We are all responsible
for our equipment.”
High Manufacturing Cost Phenomena
Machine
Machine breakdown
No Cleaning
•Rusting Occurs
•Foundation Fixers loose
•Misalignment
•Vibration
•Generation of heat
•Deformation of material
property
•High Friction
•Extra load on Machine
•Misalignment
•Vibration
No Lubrication
Availability lost
•Machine Time Lost
•Design parameters Lost
•Speed Efficiency Lost
Process Efficiency Lost
•Low production
•Low Operators
Confidence
•Low OEE
Quality Lost
•Loss of Raw Material
•Loss of Manpower due to
Rework
•Low production
•No customer Satisfaction
on product quality & delivery
High Manufacturing Cost
No Tightening
6 Manufacturing Looses
OEE Calculation
Big Idea
Reducing the manufacturing cost by increasing the equipment efficiency
 Getting operators involved in maintaining their own equipment and
emphasizing proactive and preventive maintenance will lay a foundation for
improved production (no breakdowns, stops and defects)
 Operators need to develop ownership of their equipment, and become full
partners with Maintenance so that they can perform as a tight-knit team to
create maximum equipment effectiveness.
 There are two components to this attack on waste — Asset care and CLT
maintenance. These components denote the close collaboration between
those who operate the machine and those who maintain the machine, both
of which drive up availability while driving down costs.
How to Sustain CLT
Implementation of CLT
The implementation of CLT is necessary to increase the sense of ownership of
equipment among the operators and developing their interest in work. The goal
of increasing production can be achieved by active participation of operators.
10 step for implementation of CLT.
1. Announcement of CLT and top management commitment
2. Outline a detailed master deployment plan
3. Classification and Responsibly of daily maintenance.
4. Launch a formal training program for selected team
5. Develop a CLT maintenance program for operators.
6. Pilot Team building
7. Identification of Tools & Cleaning Material required at different station.
8. Establish basic CLT policies and quantifiable goals
9. Develop a preventive maintenance plan
10. Follow ups and Continuous improvement
Classification and Allocation of Maintenance tasks
Target Technique Activity Prod. Maint.
Overallequipmenteffectivenessatleast85%
Maintenanceactivities
Prevent Deterioration Measure
Deterioration
Restore Deterioration
Normal Operation
Correct Operation O
Correct Adjustment O
Daily
Maintenance
Cleaning-expose and deal
with flaws
O
Lubricating O
Tightening O
Check deterioration and condition of use daily O
Minor servicing O
Periodic Maintenance
Periodic Checking O O
Periodic Inspection (Testing) O
Periodic Servicing O
Predictive
Maintenance
Trend Inspection O
Medium-Interval and long-interval servicing O
Breakdown
Maintenance
Prompt rapid detection of abnormalities, prompt action and reporting O O
Recurrence
prevention
O O
Emergency
repairs
O
activity
Corrective
Maintenance
(Improve reliability)
Simplification O O
Load leveling O O
Improve control
precision
O O
Reports
 % Improvement in Availability.
 % Improvement in Performance.
 % Improvement in Quality.
 % Improvement in OEE/OPE.
 % Reduction in maintenance cost.
 % Reduction in Manufacturing cost.
CLT effectiveness indicators
Effectiveness Report
on
Indicator
Management
Operating Profit Ratio of operating profit to gross capital
Cost Reduction Equipment Investment Efficiency
Labour productivity Plant / labour ratio
Plant Effectiveness
Availability % Performance %
Quality % OEE % (Overall Equipment Efficiency)
Quality
Process Defect rate No. of warranty Claims
Cost of Process defect Value of Warranty Claims
No. of Process Defect Passed Overall Yield
Energy Saving
Electricity Consumption Water Consumption
Fuel Consumption Lubricant/Fluid Consumption
Steam Consumption Auxiliary material Consumption
Maintenance
Failure Frequency Unit maintenance cost
Failure severity rate PM achievement rate
Emergency maintenance rate Overall Maintenance cost rate
Health, Safety and
Environment
Accident frequency No. of danger points spotted by safety patrols
Accident severity rate No. of improvements made to dangerous work
No. of near-miss detected No. of accidents requiring time off work
Analysis of CLT Results
Cost Reduction Labour productivity
CLT ver1.00

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CLT ver1.00

  • 2. Mission  80% OPE (Overall Plant Efficiency).  90% OEE (Overall Equipment effectiveness).  100% in delivering the goods to costumers.  Work in accident free environment.  Develop Multi-skilled and flexible workers.  Higher confidence level among the employees  Work place cleans, neat and attractive.  Favourable change in the attitude of the operators.  Achieve goals by working as team.  Share knowledge and experience.
  • 3. Strategic Goal By implementing CLT (A maintenance tool) in the manufacturing industries. To reduce manufacturing cost To Improve the OEE (Overall Equipment Efficiency To minimize the manufacturing losses (Downtime loss, Speed loss and Quality loss)
  • 4. What is CLT ? CLT is a basic medical science for machine in manufacturing. It is a simple tool to keep the manufacturing plant in a healthy state which can deliver at maximum efficiency. C: Cleaning – Eliminating dirt, dust, exposing all abnormalities, correcting minor flaws and establishing basic equipment condition. L: Lubricating – Reduce the Friction, Heat Generation, Overloading. T: Tightening - It only takes one loose bolt to start a chain of reaction of wear and vibration, as a machine vibrates slightly, other bolts work loose, vibration feeds on vibration, the equipment starts to rattle and shake, tiny cracks widen into gaping splits, parts become damaged and the result is major breakdown.
  • 5. Introduction of CLT  Manufacturing  Maintenance  Operations  Design Engineering  Plant and Site Management  Project Engineering  Engineering  Inventory and Stores In order to properly understand the impact of CLT, it is necessary to establish a definition. CLT (Cleaning/Lubricating/Tightening) is maintenance activities that are productive and implemented by all employees. CLT involves everyone in the organization from operators to senior management in equipment improvement. It encompasses all departments including:
  • 6. Cost-Benefit Strategic Goals  Productivity 100-200% increases 50-100% increase in rates of operation. 500% decrease in breakdowns  Quality 100% decrease in defects. 50% decrease in client claims  Costs 50% decrease in labour costs. 30% decrease in maintenance costs 30% decrease in energy costs  Inventory 50% reduction on inventory levels. 100% increase in inventory turns  Safety Elimination of environmental and safety violations  Morale 200% increase in suggestions Increased participation of employees in small group meetings
  • 7. CLT Philosophy Old Attitude “I operate, you fix.” “I fix, you design.” “I design, you operate.” CLT Attitude “We are all responsible for our equipment.”
  • 8. High Manufacturing Cost Phenomena Machine Machine breakdown No Cleaning •Rusting Occurs •Foundation Fixers loose •Misalignment •Vibration •Generation of heat •Deformation of material property •High Friction •Extra load on Machine •Misalignment •Vibration No Lubrication Availability lost •Machine Time Lost •Design parameters Lost •Speed Efficiency Lost Process Efficiency Lost •Low production •Low Operators Confidence •Low OEE Quality Lost •Loss of Raw Material •Loss of Manpower due to Rework •Low production •No customer Satisfaction on product quality & delivery High Manufacturing Cost No Tightening
  • 11. Big Idea Reducing the manufacturing cost by increasing the equipment efficiency  Getting operators involved in maintaining their own equipment and emphasizing proactive and preventive maintenance will lay a foundation for improved production (no breakdowns, stops and defects)  Operators need to develop ownership of their equipment, and become full partners with Maintenance so that they can perform as a tight-knit team to create maximum equipment effectiveness.  There are two components to this attack on waste — Asset care and CLT maintenance. These components denote the close collaboration between those who operate the machine and those who maintain the machine, both of which drive up availability while driving down costs.
  • 13. Implementation of CLT The implementation of CLT is necessary to increase the sense of ownership of equipment among the operators and developing their interest in work. The goal of increasing production can be achieved by active participation of operators. 10 step for implementation of CLT. 1. Announcement of CLT and top management commitment 2. Outline a detailed master deployment plan 3. Classification and Responsibly of daily maintenance. 4. Launch a formal training program for selected team 5. Develop a CLT maintenance program for operators. 6. Pilot Team building 7. Identification of Tools & Cleaning Material required at different station. 8. Establish basic CLT policies and quantifiable goals 9. Develop a preventive maintenance plan 10. Follow ups and Continuous improvement
  • 14. Classification and Allocation of Maintenance tasks Target Technique Activity Prod. Maint. Overallequipmenteffectivenessatleast85% Maintenanceactivities Prevent Deterioration Measure Deterioration Restore Deterioration Normal Operation Correct Operation O Correct Adjustment O Daily Maintenance Cleaning-expose and deal with flaws O Lubricating O Tightening O Check deterioration and condition of use daily O Minor servicing O Periodic Maintenance Periodic Checking O O Periodic Inspection (Testing) O Periodic Servicing O Predictive Maintenance Trend Inspection O Medium-Interval and long-interval servicing O Breakdown Maintenance Prompt rapid detection of abnormalities, prompt action and reporting O O Recurrence prevention O O Emergency repairs O activity Corrective Maintenance (Improve reliability) Simplification O O Load leveling O O Improve control precision O O
  • 15. Reports  % Improvement in Availability.  % Improvement in Performance.  % Improvement in Quality.  % Improvement in OEE/OPE.  % Reduction in maintenance cost.  % Reduction in Manufacturing cost.
  • 16. CLT effectiveness indicators Effectiveness Report on Indicator Management Operating Profit Ratio of operating profit to gross capital Cost Reduction Equipment Investment Efficiency Labour productivity Plant / labour ratio Plant Effectiveness Availability % Performance % Quality % OEE % (Overall Equipment Efficiency) Quality Process Defect rate No. of warranty Claims Cost of Process defect Value of Warranty Claims No. of Process Defect Passed Overall Yield Energy Saving Electricity Consumption Water Consumption Fuel Consumption Lubricant/Fluid Consumption Steam Consumption Auxiliary material Consumption Maintenance Failure Frequency Unit maintenance cost Failure severity rate PM achievement rate Emergency maintenance rate Overall Maintenance cost rate Health, Safety and Environment Accident frequency No. of danger points spotted by safety patrols Accident severity rate No. of improvements made to dangerous work No. of near-miss detected No. of accidents requiring time off work Analysis of CLT Results Cost Reduction Labour productivity