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