Let’s say a Technician gets paid $20 an hour. The Tech is told to do a 6-month PM on the Haas Mill. He needs to change the coolant, inspect the hoses, and check the Rotary Table oil level.
⦁ He walks out to the machine and pulls the coolant tank out.
20 minutes.
⦁ He realizes he needs a pump and container for the old coolant. He goes back to the shop and gets the pump and container.
20 minutes.
⦁ Starts to pump out the coolant and discovers his container won’t hold all the old coolant. He has to go back to the shop to get another container.
20 minutes.
⦁ He is thinking ahead and now he knows how much coolant he needs, so grabs the new coolant while he is in the shop.
10 minutes.
⦁ He finishes pumping out the old coolant and starts to add the new coolant. He does not know the coolant concentration, so he has to go back to the shop and look it up in the manual.
30 minutes.
⦁ He mixes the coolant and fills up the tank. To make up time, he starts to inspect the hoses and checks the oil level of the Rotary Table, while filling the tank. The Rotary table is low on oil. He has to go to the shop and look up the oil type. He gets the oil and goes back to the machine.
20 minutes
Now with the following work instructions, the Technician’s day looks more like this:
⦁ CHANGE coolant and CLEAN coolant tank.
⦁ PULL the tank out from under the machine.
⦁ REMOVE the standard pump from the coolant tank.
⦁ REMOVE the TSC pump from the coolant tank.
⦁ REMOVE/CLEAN TSC pump filter box and screen.
⦁ REMOVE/CLEAN gate filter.
⦁ REMOVE/CLEAN chip tray.
⦁ REMOVE old coolant.
⦁ CLEAN coolant tank.
⦁ REPLACE coolant (approx. 55 gals.)
⦁ ENSURE the coolant mixture is between 6% and 7%.
⦁ INSPECT all hoses and lubrication lines for cracking or damage.
⦁ INSPECT the HRT310 Rotary A-axis Table.
⦁ ADD oil to oil tank, if needed. Mobil SHC-630 or equivalent.
The Tech spends 5 minutes reading the Work Order. Another 10 minutes getting the coolant, container, pump and oil gathered up. Get goes to the machine and spends 100% wrench time on the job.
Results:
Without proper planning, the Tech spent 2 hours ($40 not including the burden rate) of wasted time in getting information and tools to do the job.
With the proper planning, the Tech only spent 15 minutes to get what he needed to do the job. He finished the job 1 hour and 45 minutes earlier so he could move onto the next job.
This job is only done every 6 months – will the Technician remember everything he needs in 6 months from now? Or will he waste another 2 hours?
Let's say you keep the machine for 6 years. That is 3 PM that a tech will waste 2 hours. ($480 not including burden rate) for just one PM.
And what about that 1:45 he could be working on something else. That is 21 hours (half of a week) extra time.
This Haas mill has a monthly, 6 month, and annual PMs.