When you have a repetitive breakdown, experts advise determining the root cause and fixing it. But that is not always feasible or possible. Maybe it’s 11 months until the next shutdown, or the line’s being discontinued soon and management won’t invest, or the fix just doesn’t pass the company’s cost/benefit analysis. But this problem adversely affects maintenance metrics and resources. If you can’t cure the problem, then cope with it better. Let’s look at two things you can do, for example.
Create a kit specifically for this repair, and store it in a specific place near the machine. Include the exact spare parts, the exact tools, and anything else that is used in the course of this repair. Make a specific individual responsible for inspecting and maintaining this kit (including reordering spare parts).
Train a specific crew for this specific repair, so they can “do it blindfolded.” Make sure they are the ones who respond when this specific failure occurs. Also train alternates for vacations, and rotate people in and out of “the A team”.
