Achieving 100% Equipment Reliability: Learning from Top NASCAR

Transcription

Achieving 100% Equipment Reliability:
Learning from Top NASCAR Teams
Robert Williamson
Strategic Work System, Inc.
Columbus, North Carolina
USA
Produced by:
Supported by:
Daytona 500 Win
Paid $1,525,275
($7,626.38/lap)
36th Place Finish
Paid $334,118
($1,670.59/lap)
Cost of failure
= $1,191,157
copyright 2013 - Robert M. Williamson - Columbus, NC USA
Failures cost!
What is the cost of failures in your plant?
Reliability pays!
What can you take away from this session?
• Six Secrets of Top NASCAR Race Teams
• Seven principles of equipment reliability
• Three factors of equipment reliability
• Common sense ideas that you can turn into
common practice in your business
Re-li-a-bil’-i-ty –
Equipment and processes doing
what they are supposed under
stated operating conditions for a
stated period of time.
Failures cost… Reliability pays!
How close to 100% reliability is
your critical equipment?
Why?
Daytona 500
February 2013
Qualifying Times
(2-1/2 Mile Track)
7/10th
second
separates the top 36
racecars
guaranteeing them
a spot in the 500
race!
1. #10 Danica Patrick Chevrolet 45.817s
2. #24 Jeff Gordon Chevrolet 45.850s
3. #21 Trevor Bayne Ford 45.924s
4. #39 Ryan Newman Chevrolet 45.931s
5. #14 Tony Stewart Chevrolet 45.936s
6. #5 Kasey Kahne Chevrolet 45.953s
7. #11 Denny Hamlin Toyota 45.972s
8. #18 Kyle Busch Toyota 45.973s
9. #22 Joey Logano Ford 45.973s
10. #20 Matt Kenseth Toyota 45.983s
11. #88 Dale Earnhardt, Jr. Chevrolet 46.016s
12. #17 Ricky Stenhouse, Jr. Ford 46.027s
(Leader) 196.434mph
(+ 0.033s) 196.292mph
(+ 0.107s) 195.976mph
(+ 0.114s) 195.946mph
(+ 0.119s) 195.925mph
(+ 0.136s) 195.852mph
(+ 0.155s) 195.771mph
(+ 0.156s) 195.767mph
(+ 0.156s) 195.767mph
(+ 0.166s) 195.725mph
(+ 0.199s) 195.584mph
(+ 0.210s) 195.537mph
13. #42 Juan Pablo Montoya Chevrolet 46.034s
14. #27 Paul Menard Chevrolet 46.035s
15. #13 Casey Mears Ford 46.037s
16. #33 Austin Dillon Chevrolet 46.063s
17. #99 Carl Edwards Ford 46.097s
18. #15 Clint Bowyer Toyota 46.100s
19. #56 Martin Truex, Jr. Toyota 46.105s
20. #31 Jeff Burton Chevrolet 46.117s
21. #48 Jimmie Johnson Chevrolet 46.134s
22. #1 Jamie McMurray Chevrolet 46.144s
23. #2 Brad Keselowski Ford 46.163s
24. #9 Marcos Ambrose Ford 46.203s
25. #29 Kevin Harvick Chevrolet 46.215s
26. #43 Aric Almirola Ford 46.215s
27. #16 Greg Biffle Ford 46.218s
28. #55 Mark Martin Toyota 46.229s
29. #38 David Gilliland Ford 46.236s
30. #34 David Ragan Ford 46.245s
31. #26 Michael Waltrip Toyota 46.317s
32. #35 Josh Wise Ford 46.331s
33. #78 Kurt Busch Chevrolet 46.474s
34. #98 Michael McDowell Ford 46.501s
35. #95 Scott Speed Ford 46.502s
36. #32 Terry Labonte Ford 46.508s
(+ 0.217s) 195.508mph
(+ 0.218s) 195.503mph
(+ 0.220s) 195.495mph
(+ 0.246s) 195.385mph
(+ 0.280s) 195.240mph
(+ 0.283s) 195.228mph
(+ 0.288s) 195.207mph
(+ 0.300s) 195.156mph
(+ 0.317s) 195.084mph
(+ 0.327s) 195.042mph
(+ 0.346s) 194.961mph
(+ 0.386s) 194.793mph
(+ 0.398s) 194.742mph
(+ 0.398s) 194.742mph
(+ 0.401s) 194.729mph
(+ 0.412s) 194.683mph
(+ 0.419s) 194.654mph
(+ 0.428s) 194.616mph
(+ 0.500s) 194.313mph
(+ 0.514s) 194.254mph
(+ 0.657s) 193.657mph
(+ 0.684s) 193.544mph
(+ 0.685s) 193.540mph
(+ 0.691s) 193.515mph
Fastest
0.691 sec
Slowest
In Pursuit of 100% Reliability…
September 3, 1956 Southern 500 stock car race,
Darlington, South Carolina:
- 70 cars started the race, 39 finished
- Margin of victory was over two laps!
- Tenth place car was down 17 laps
- Nineteen (19) mechanical failures, 12 crashes
- Curtis Turner in a 1956 Ford won $11,750
September 1, 2002 Southern 500 stock car race,
- 43 cars started the race, 37 finished
- Margin of victory was 1.734 seconds!
- Twenty-three (23) cars were on the lead lap
- Two (2) mechanical failures, 4 crashes
- Jeff Gordon in a Chevy won $217,183
August 31, 2003 Southern 500 stock car race,
- 43 cars started the race, 37 finished.
- Margin of victory was 1.651 seconds!
- Sixteen (16) cars were on the lead lap.
- One (1) had electrical failure, 5 crashes.
- Terry Labonte in a Chevy won $204,736.
Ryan Newman #12 Alltel Dodge led 120 laps, lost 8 laps !
Failures cost…
Reliability pays!
Radio
Switch
New “Kill”
Switch
The seven principles of
equipment reliability...
#1
Reliable
Equipment data
Daytona 500 February 2013
Finishing Position
0.129
Sec.
Pos
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
No.
48
88
55
2
39
16
51
10
98
36
15
17
43
11
47
83
7
9
22
24
27
26
95
56
93
32
21
78
13
31
33
1
99
18
34
5
20
38
42
35
14
29
87
Driver
Jimmie Johnson
Dale Earnhardt, Jr.
Mark Martin
Brad Keselowski
Ryan Newman
Greg Biffle
Regan Smith
Danica Patrick
Michael McDowell
J. J. Yeley
Clint Bowyer
Ricky Stenhouse, Jr.
Aric Almirola
Denny Hamlin
Bobby Labonte
David Reutimann
Dave Blaney
Marcos Ambrose
Joey Logano
Jeff Gordon
Paul Menard
Michael Waltrip
Scott Speed
Martin Truex, Jr.
Travis Kvapil
Terry Labonte
Trevor Bayne
Kurt Busch
Casey Mears
Jeff Burton
Austin Dillon
Jamie McMurray
Carl Edwards
Kyle Busch
David Ragan
Kasey Kahne
Matt Kenseth
David Gilliland
Juan Pablo Montoya
Josh Wise
Tony Stewart
Kevin Harvick
Joe Nemechek
Team
Hendrick Motorsports
Michael Waltrip Racing
Penske Racing
Stewart-Haas Racing
Roush Fenway Racing
Phoenix Racing
Stewart-Haas Racing
Phil Parsons Racing
Tommy Baldwin Racing
Roush Fenway Racing
Richard Petty Motorsports
Joe Gibbs Racing
JTG Daugherty Racing
BK Racing
Tommy Baldwin Racing
Richard Petty Motorsports
Penske Racing
Richard Childress Racing
Swan Racing
Leavine Family Racing
BK Racing
FAS Lane Racing
Wood Brothers Racing
Furniture Row Racing
Germain Racing
Earnhardt Ganassi Racing
Roush Fenway Racing
Joe Gibbs Racing
Front Row Motorsports
Joe Gibbs Racing
Earnhardt Ganassi Racing
Stewart-Haas Racing
NEMCO Motorsports
Qualifying Times
1. #10 Danica Patrick Chevrolet 45.817s
2. #24 Jeff Gordon Chevrolet 45.850s
3. #21 Trevor Bayne Ford 45.924s
4. #39 Ryan Newman Chevrolet 45.931s
5. #14 Tony Stewart Chevrolet 45.936s
6. #5 Kasey Kahne Chevrolet 45.953s
7. #11 Denny Hamlin Toyota 45.972s
8. #18 Kyle Busch Toyota 45.973s
9. #22 Joey Logano Ford 45.973s
10. #20 Matt Kenseth Toyota 45.983s
11. #88 Dale Earnhardt, Jr. Chevrolet 46.016s
12. #17 Ricky Stenhouse, Jr. Ford 46.027s
13. #42 Juan Pablo Montoya Chevrolet 46.034s
14. #27 Paul Menard Chevrolet 46.035s
15. #13 Casey Mears Ford 46.037s
16. #33 Austin Dillon Chevrolet 46.063s
17. #99 Carl Edwards Ford 46.097s
18. #15 Clint Bowyer Toyota 46.100s
19. #56 Martin Truex, Jr. Toyota 46.105s
20. #31 Jeff Burton Chevrolet 46.117s
21. #48 Jimmie Johnson Chevrolet 46.134s
22. #1 Jamie McMurray Chevrolet 46.144s
23. #2 Brad Keselowski Ford 46.163s
24. #9 Marcos Ambrose Ford 46.203s
25. #29 Kevin Harvick Chevrolet 46.215s
26. #43 Aric Almirola Ford 46.215s
27. #16 Greg Biffle Ford 46.218s
28. #55 Mark Martin Toyota 46.229s
29. #38 David Gilliland Ford 46.236s
30. #34 David Ragan Ford 46.245s
31. #26 Michael Waltrip Toyota 46.317s
32. #35 Josh Wise Ford 46.331s
33. #78 Kurt Busch Chevrolet 46.474s
34. #98 Michael McDowell Ford 46.501s
35. #95 Scott Speed Ford 46.502s
36. #32 Terry Labonte Ford 46.508s
Manufacturer
Chevrolet
Chevrolet
Toyota
Ford
Chevrolet
Ford
Chevrolet
Chevrolet
Ford
Chevrolet
Toyota
Ford
Ford
Toyota
Toyota
Toyota
Chevrolet
Ford
Ford
Chevrolet
Chevrolet
Toyota
Ford
Toyota
Toyota
Ford
Ford
Chevrolet
Ford
Chevrolet
Chevrolet
Chevrolet
Ford
Toyota
Ford
Chevrolet
Toyota
Ford
Chevrolet
Ford
Chevrolet
Chevrolet
Toyota copyright 2013 - Robert M. Williamson - Columbus, NC USA
WHY?
(Leader) 196.434mph
(+ 0.033s) 196.292mph
(+ 0.107s) 195.976mph
(+ 0.114s) 195.946mph
(+ 0.119s) 195.925mph
(+ 0.136s) 195.852mph
(+ 0.155s) 195.771mph
(+ 0.156s) 195.767mph
(+ 0.156s) 195.767mph
(+ 0.166s) 195.725mph
(+ 0.199s) 195.584mph
(+ 0.210s) 195.537mph
(+ 0.217s) 195.508mph
(+ 0.218s) 195.503mph
(+ 0.220s) 195.495mph
(+ 0.246s) 195.385mph
(+ 0.280s) 195.240mph
(+ 0.283s) 195.228mph
(+ 0.288s) 195.207mph
(+ 0.300s) 195.156mph
(+ 0.317s) 195.084mph
(+ 0.327s) 195.042mph
(+ 0.346s) 194.961mph
(+ 0.386s) 194.793mph
(+ 0.398s) 194.742mph
(+ 0.398s) 194.742mph
(+ 0.401s) 194.729mph
(+ 0.412s) 194.683mph
(+ 0.419s) 194.654mph
(+ 0.428s) 194.616mph
(+ 0.500s) 194.313mph
(+ 0.514s) 194.254mph
(+ 0.657s) 193.657mph
(+ 0.684s) 193.544mph
(+ 0.685s) 193.540mph
(+ 0.691s) 193.515mph
0.691
Sec.
Targeting the major causes of poor performance
If you don’t
measure it,
then you cannot
improve it!
Targeting the major causes of poor performance
ACTION!
REILABLE
DATA
INFORMATION
KNOWLEDGE
#2
Operations involvement
Alan Gustafson, #24 Crew Chief
“I’m not reading the numbers on those gauges…”
Jeff Gordon, Driver #24 DuPont Chevy
#3
Maintenance efficiency and
effectiveness
“Inspecting parts
before we put them
on the shelf”
“We store our parts so they can’t be damaged”
Logging lubrication changes ON the equipment
Standardizing
everything
that’s critical
Pit stops: “Planned maintenance downtime”
#1 Priority:
Fast or right?
Photo © 2011 by Robert Williamson
“Why change? We’ve always done it this way”
Average NASCAR Pit Stop Times…
1950s
Wood Brothers
Choreographed pit stops
1960
3-4 min.
1 min.
#48 Lowe’s car at
Darlington Spring race
3 @ 12.6 sec.
1964
1993
2001
20 sec.
17 sec.
13.4 sec.
1950s
2004
12.6 sec.
1952 NASCAR Racing Pit Stop…
1958 NASCAR Racing Daytona Beach Pit Stop…
1959 NASCAR Racing Daytona 500 Pit Stop…
1959 NASCAR Racing Daytona 500 Pit Stop…
2009 Pit Stop Training & Practice (Trainees)…
“Why change? We’ve always done it this way”
Goal: Low cost, high value, on time provider… But,
Fewer people entering careers in facilities & plant maintenance
Best & brightest “go to college & don’t get your hands dirty…”
Vocational Technical skills training program decline
Global supply chain chaos
Low bid, budget constraints
Counterfeit spare parts
33
#4
Training & learning to improve skills & knowledge
“Best Practices”
Standardized procedures, training &
accountability to follow the procedures
eliminates problems.
Goethe
Checklists & visual cues serve as
reminders and help prevent errors.
If you can’t standardize it you can’t improve it.
(Edwards Deming)
Tire Carrier makes a
chassis adjustment
AFTER putting the tire
on the car, removes
the tool, & carries
back to pit wall
Tire Changer removes
& replaces 5 lug nuts (1
sec off, 1.2 sec on)
Jack Man removes tire
and positions for Tire
Carrier to return to pit
wall…
“The ability to learn faster than your
competitors may be the only sustainable
competitive advantage”
Arie de Geus
Author, “The Living Company”
Former, Shell Oil Company
Strategic Planning Group
#5
Operability & maintainability
improvement
Making it easier to maintain
Lug nuts glued to
wheel…
Both valve stems
in line & opposite
12 o’clock
12 o’clock lug nut & tape
Left Front 6th set
1.0 ounce wheel
weight goes here
(missing!)
Grab here
2013NC
- Robert
copyright 2013 - Robert M. Williamsoncopyright
- Columbus,
USA M. Williamson - Columbus, NC USA
Making it easier to maintain
 Race-modified “race gun”: $1,500
 Nitrogen powered: 110psi
 18,000 rpm
 1,000lb-ft torque
 Special $60
socket:
(one race!)
 1-1/8” socket
for 1” lug nut
#6
Focused Teamwork &
Leadership
c. 2011
Team: “a group
of people focusing on
common goals using
common processes”
#1 Priority:
Fast or right?
People, is
Teamwork,
Leadership & Equipment
Reliability
“Winning
EVERYONE’S
responsibility!”
Owner
#1 Priority: Fast or right?
Business Manager
Most important role?
Records Assistant
Driver
Car Chief
Sponsors
Pit Crew
Team Manager
Shop Manager
Pit Crew Coach
Supplies & Vendors
Pit Support
Spotter
Machine Shop
Parts & Supplies
Management
Crew Chief
Tire Specialist
Engineers
NASCAR Officials
Suspension Shop
Chassis fab Shop
Engine Tuner
Mechanics
Most critical?
Engine Builders
Body Shop
Paint Shop
Direct influence
Indirect influence
Who makes it win?
Three Factors of Reliability - In Pursuit of 100%
PEOPLE
Applied Skills &
Knowledge
WORK
PROCESSES
Work Culture
RELIABLE
EQUIPMENT
54
In a competitive environment to remain the same…
Common Sense?
What if you started to treat your
critical equipment like a race car?
Failures cost… Reliability pays!
What if you had a race car and treated it
like the equipment in your plant?
Common Practice?
Work Culture
Focus - - - on - - - Results…
and change the culture along the way
Slide 58
#7
Focused Teamwork &
Leadership
Reliable
Equipment data
Operations involvement
Focus - - - on - - - Results…
Operability & maintainability
improvement
Maintenance efficiency and
effectiveness
Training & learning to improve skills & knowledge
Six Secrets of Top NASCAR Race Teams:
1.
“If we can’t finish, we can’t win”
• Equipment reliability is a must
2.
“We win or lose together”
•
3.
“Go slow to go fast”
•
4.
Plan your work and work your plan
“If you stay the same you’re losing ground”
•
6.
Right the first time, every time - flawless human performance
“The green flag drops at 1 o’clock on Sunday… whether you’re ready or not”
•
5.
Leadership & teamwork focused on common strategic goals
Not satisfied with status quo. Continuous (ongoing) improvement
“If you’re not cheating you’re not racing”
•
Think inside AND outside the box for a better way (see #5)
Failures cost.
Reliability pays!
The right tools,
the right skills
& knowledge,
first time,
every time.
Achieving 100% Equipment Reliability:
Learning from Top NASCAR Teams
You can do it too!
Robert (Bob) Williamson
Strategic Work Systems, Inc.
Pit Crew
Email: [email protected]
Web site: www.swspitcrew.com
USA: 828-894-5338
Seven interdependent principles of equipment reliability
1. Targeting the major causes of poor performance (Reliable data)
2. Operations involvement
3. Efficient & effective maintenance, repair, & overhaul
4. Training to improve skills and knowledge
5. Operability & maintainability improvement
6. Leadership & teamwork focused on strategic goals
7. Focus on results and change the culture along the way
NASCAR Race Team critical success factors that apply to business & industry:
1. Leadership & teamwork focused on common goals with a line of sight to strategic business
goals: two-way communication
2. Set very clear expectations, accountabilities, and make resources available
3. Knock down barriers that prevent the goals from being achieved and sustained
4. Plan, brief/practice, execute, then debrief: The path to flawless human performance
5. The right people with the right skills doing the right things at the right time (consistency)
6. Know how you perform compared to a baseline, your competition. Measure, track, trend,
report, analyze the right things (Facts vs. opinions)
7. Expect 100% reliability at peak performance levels of your most critical equipment
8. Failure is not an option. When it happens learn from it… fast!
9. Focused, laser-like focus on causes of poor performance
10. Always look for a better way in everything you do
64
"Why is it that we often struggle to improve the
way our equipment and facilities run - faster,
better, more consistently?
It should be a lot easier... and it can be easy.
Reliability is more about the 'human factors' than
it is about new technologies and tools.“
Robert Williamson
www.MT-Online.com
Robert (Bob) Williamson is a workplace educator with nearly 40 years or experience
helping companies and workgroups improve the performance of their equipment and work
processes through applied education and training. His background in maintenance
mechanics, special machine and tooling design, and teaching vocational/technical courses
has prepared him for a career that has taken him into well over 400 plant and company
locations developing operations and maintenance training, Total Productive Maintenance
development, multi-skill maintenance job design, pay-for-applied skills design, and “Lean
Equipment Management.” After 24 years in post-secondary technical education and plant
engineering/construction he formed Strategic Work Systems, Inc. in 1993 to focus on the
people-side of world class manufacturing and maintenance. He has also studied and taught
the “team-based reliability” principles from NASCAR Racing for over 20 years. Recent
publications have stated that…
“Bob probably knows more about Lean Maintenance and NASCAR
than any other person on earth.”
His hundreds of articles and conference papers since the mid 1980s have addressed the
“people-side of manufacturing and maintenance/reliability.” Check out the web site below
for an archive of recent articles.
© 2011 All rights reserved.
Robert M. Williamson
Strategic Work Systems, Inc.
PO Box 70 - Columbus, NC 28722 828/894-5338
Email: [email protected]
Web site: www.swspitcrew.com
Pit Crew

Achieving 100% Equipment Reliability: Learning from Top NASCAR

Transcription

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