SKF do Brasil

© SKF Group

SKF do Brasil

© SKF Group

© SKF Group

SKF do Brasil - Automotiva

Valid from: 2016-02-24

• A SKF é um fornecedor líder global de tecnologia desde 1907;

• 101 anos em 2016 no BRASIL;

SKF Excelência Manutenção

© SKF Group

© SKF Group 16-12-08Slide 3

Linha de produção - Cajamar

© SKF Group


Produtos – mercado automobilístico

MSBU

TRB

HBU 1

HBU 1T

HBU 2 HBU 3

TMU / THU CRB

Nova linha 2017

© SKF Group


Produtos – mercado de distribuição

© SKF Group


Kaydon – bearing for wind power

© SKF Group


Centro distribuição em Jordanésia

© SKF Group


Principais clientes – mercado automotivo

Slide 8

• Brazil

• Argentina

• Germany

• Brazil

• Argentina

• Italy

• Brazil

• Germany

• Brazil

• USA

• Korea

• Germany

• Korea

• Brazil

• Germany

• Brazil

© SKF Group

© SKF Group

SKF Business Excellence

8 December 2016

Slide 9

A ponte da Excelência dos Negócios é um símbolo de nosso trabalho que ilustra a busca pela

excelência em todos os nossos negócios.

Sistema de ProduçãoSKF Brasil

© SKF Group

© SKF Group

Slide 11

Historico, Evolução e Futuro

2001

2004

2007

2009ME

Futuro:

Excelência em Negócios

2003

2011

DFSS & WB

2012

BE Triangule

© SKF Group


Construindo nosso plano estratégico

© SKF Group

© SKF Group

Prioridades da Manufatura

1

2

3

4

5

6

Segurança

Qualidade

Entrega

Custo

Motivação

Meio Ambiente

Comportamentos

Resultados

Treinando os treinadores

© SKF Group

© SKF Group

Treinando os treinadores

Slide 15

© SKF Group


Gestão de indicadores – tempo real

Channel Dashboard

Factory Dashboard

Realtime OEE measurements Losses Bar Chart

Testing

© SKF Group


5S – gerenciamento visual

© SKF Group


Melhoria ergonômica – posto trabalho

K1K2

K4

K3

K1

K3

K2/K4

Kaizen

© SKF Group


Gestão diária dos desvios

T.L perform the DM Level 1

with the team members

7:15 / 19:15 – 15 min

T.L perform the DM Level 2

with Support functions +

Channel Manager

7:45/ 19:45 – 15 min

Channel Manager

Perform DM Level 3

8:00/ 20:00 – 15 min

Shift hand over preparation:

deviations still present:

5:50 / 17:50 – 5 min

Shift handover - T.L report the

deviations to the next shift T.L

5:55 / 17:55– 5 min

1 2 3

4 5

© SKF Group


Setup – reunião estratégia de atuaçãoE

ntr

eg

a g

uia

da p

elo

valo

r do c

liente

© SKF Group

© SKF Group

Capacitando os lideresN

ós C

uid

am

os

• Meu papel como Agente de Segurança;

• Liderança e Sistemática de Treinamento

Prático;

• Solução de Desvios ( White Belt);

• Qualidade no Canal de Produção;

• Programação de Produção;

• Estratégia de SETUP;

• Facilitador de 5S e TPM;

• Como Facilitar Reunião Diária;

• Controle de Abrasivos;

• Fluxo de Apontamento de Sucata;

• Fundamentos do Trabalho Padronizado;

• Cadeia de Ajuda (Help Chain);

Foco no desenvolvimento da

liderança de primeiro nível

Confiabilidade de maquinas

© SKF Group


Relacionamento Produção x Manutenção

I need to

Produce !!!

I need to

repair the

machines !!!

• Superficial Analysis of

Problems

• Reactive Actions

• No Spare Parts

• No Machine History

• Corrective Maintenance

• Focus only on Production

• No Teamwork

• No basics procedures

© SKF Group

© SKF Group

Auditorias de 5S - Manutenção Preventiva - TRB C2

Busca da Estabilidade…

Auditória de 5S

Inspeção Autonoma - 15 minutos por turno

© SKF Group

© SKF Group

Slide 25

Excelência na Manutenção

MVM

MGE

CANAL 4 (HBU)

CANAL 9 (TRB)

MVR

CANAL 1 (TRB)

CANAL 21 (HBU)

MVU

MVR

CANAL 2 (TRB)

MVR

MGE

CANAL 6 (TRB)

MVR

© SKF Group


Analise sistema de quebra

Foco Aumento da Estabilidade

© SKF Group

© SKF Group


Procedimentos e Instruções


© SKF Group

© SKF Group


Manutenção Preditiva (Técnicas)


Análise Vibração

ODR

Operation Drive Reliability

Alinhamento de Eixos

Termografia

Análse de Óleo

© SKF Group

© SKF Group


Manutenção Autônoma


Plano de Lubrificação

Check List da MA

Check List da MA

Check List da MACheck List da MA

© SKF Group

© SKF Group


INDICADORES


• Custos;

• Performance Manutenção vs Produção;

D’time, MTBF, MTTR, Preventivas e Corretivas;

Sejam Bem Vindos!

© SKF Group

Maintenance Excellence

KPI - Key Performance Indicator

SKF do Brasil – Cajamar - 2016

Wellington Genezini

Coordenador Manutenção

[email protected]

mailto:[email protected]

© SKF Group

Maintenance Excellence -10 Sistemas

1. Maintenance Organization & Competence1. Set right organization and ensure maintenance skill

requirements are met

2. KPI´s & Cost 2. Understand and manage maintenance costs

3. Autonomous Maintenance3. Build operator capability to establish & maintain

machine basic condition

4. Planned Maintenance 4. Maintain equipment in optimal condition

5. Break down Elimination 5. Eliminate equipment failures & prevent recurrence

6. CMMS ( API ) 6. Leverage API to simplify maintenance

7. Planning & Scheduling7. Planning & Scheduling all maintenance activities in

advance and perform

8. Spare Parts Management 8. Maintain optimal inventory of critical spare parts

9. Reliability Engineering 9. Analyze failure and cost data to drive improvements

10. Early Equipment Management 10. Build equipment's & machines to be reliable

© SKF Group

Maintenance Excellence - EspectativasSKF Production

System

Phase 1

Transition

Phase 2

Expansion

Phase 3

Acceleration

AMPilot

Step 1-3

Back to Basics

Step 4-5

Maintenance

Training

Step 6 - 7

Keep & Improve

ideal condition

Factory Step 1 - 3 Step 4 - 7

PMPilot

Step 1

Evaluate &

Define

Maintenance

Strategy

A/B/C

Step 2

Support Back to Basics

Step 3

Optimize CMMS

Step 4

Define

Maintenance

Program

Step 5

Implement

Maintenance

Program

Step 6

Optimize

Maintenance

Systems

Factory Step 2-5 Step 6

Expected Results

Bread Down reduced > 50% BD reduced > 80% BD rarely occur

Costs reduced > 5% Costs reduced >

10%

Costs reduced >

20%

Spare Parts Organization Spare parts

optimization

Spare parts

improving

50% of Maintenance personal time are in Planning & Scheduling 60% time in P&S 85% time in P&S

PM Schedule compliance. > 60% PM comp. > 90% PM Comp > 95%

© SKF Group

KPIs – Maintenance SKF Cajamar

Portal of Maintenance Indicators - 2016

Customer's

Voice

Customer's

Voice

Inventory and

Overtime Costs

and Overtime

MTBF Worst

Analyzes and

Action Plan

Predictive

Maintenance,

Operational

Utilities and

Spare Parts

Planned /

Preventive

Maintenance

© SKF Group

© SKF Group

KPIs – Maintenance SKF CajamarD’Time

D'time indicator

through faces...

3 Worst D’time of

the Factory in the

month…

Goo

d

Ba

d

Goa

l

D'time Indicator

by Production

Channels…

Source: API Pro + Key data

© SKF Group

© SKF Group

KPIs – Maintenance SKF CajamarD’Time vs MTBF

D'Time indicator

and MTBF

detailed by

channels and

month

Source: API Pro

© SKF Group

© SKF Group

KPIs – Maintenance SKF CajamarBad Actors MTBF

Detailed MTBF

indicator by

channels, month

and criticality

Source: API Pro

© SKF Group

© SKF Group

KPIs – Maintenance SKF CajamarBad Actors MTBF

MTBF Analysis

of the 5 Worst

Detailed

Source: API Pro

© SKF Group

© SKF Group

KPIs – Maintenance SKF CajamarPreventive Maintenance vs Corrective Maintenance

Source: API Pro

© SKF Group

© SKF Group

KPIs – Maintenance SKF CajamarMost Consumable Parts

Unavailability of

Spare Parts

Source: API Pro

© SKF Group

© SKF Group

KPIs – Maintenance SKF CajamarUtilities Operations

Color light

Unavailability of

Utilities

Daily Logbook

Utilities

Source: Logbook

© SKF Group

© SKF Group


Daily Logbook

Utilities

Unavailability of

UtilitiesIndicator of

Consumption of

Hydraulic Filters

and Filtration

Papers

Indicator of

Consumption of

Hydraulic Filters

and Filtration

Papers

Monthly

Consumption

Color Light

Color Light Daily

Consumption

Source: Logbook

© SKF Group

© SKF Group


Plan of action

indicator out

month

Central Utilities

Tanks

Central Utilities

Tanks

Monthly Analysis

Monthly Consumption Control

Control of Daily Consumption

Source: Logbook

SKF do Brasil

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