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FORD PRODUCTION SYSTEM

Integrated Operating Systems

Maintenance Operating
System

GFPS-MOS
Title: Comm_GFPS_6_MOS_Overview GIS1 Item #: N/A - Transient Document
Revision Date: 12June2012 Page 1 of 7 GIS2 Classification: Proprietary
Printed Copies are Uncontrolled Retention Code: S
The Global Ford Production System
Integrated Operating Systems
Operating
System Maintenance Operating System
Vision
A Standardized, Proactive and Disciplined Operating
System that engages all team members to maintain
the integrity and availability of equipment, facilities
and processes.

Goal
Optimize resources to maximize through-put to
potential of equipment and facilities with ZERO
unplanned downtime

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The Global Ford Production System
Integrated Operating Systems
Operating
System Maintenance Operating System
Principles
• Safety & Quality are never compromised
• Maintenance is owned by Manufacturing
• Use data to make decisions
• Standardized tools, practices & procedures
• Drive root cause and prevention through a Continuous
Improvement Process
• Utilize Total Cost over the life of equipment
• Optimize resources at the lowest possible cost
• Maintain the integrity of the equipment (over the long term)
• Communicate Lessons Learned and Process Improvements
• Maximize through-put of installed equipment and facilities to its
potential
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The Global Ford Production System
Integrated Operating Systems
Operating
System Maintenance Operating System
REACTIVE REACTIVE
Input(s) Key Process & Sub-Processes Metric(s) Goal(s)
ANDON ANDON
1. People 1. Constraint Management and Prioritization
• Identify and Prioritize Constraints
• Trained, Versatile
• Identify Losses and Causal Factors
JPH to Optimize
Personnel • Potential
• Technically 1. Current •
Develop and Prioritize Corrective Actions
Implement Corrective Actions 1. % PMs resources to
versatility Complete to
Competent
matrix 2. Planning and Scheduling Schedule achieve
Leadership

Through-put
• Defined R & R and 2. Manpower

Identify and Prioritize Work
Identify Resource Needs (equipment, material and people).
(Plant,
Constraint, to Target 100%
Org Structure available
• Communication (RTO) vs
• Develop and Finalize Plan (includes approval) SOS, QOS (e.g. Hits vs. Hits utilization of
• Schedule Resources and Acquire Materials. EOS)
Manpower
• Communicate the Plan
Available) equipment
2. Machine required (Est
• Affordable hrs) 3. Execute Planned Maintenance 2. Constraint with ZERO
3. Verify backup • Perform Preventive Maintenance performance
Maintainability
• Robust and processes • Perform Predictive Maintenance unplanned
• Perform Corrective Maintenance 3. Planned vs
Realistic required ready to run
• Perform Autonomous Maintenance Crisis Downtime
PM from OEM 4. Validation of
systems data 4. Optimize Maintenance
(Operating hours • Analyze Production and Maintenance performance data 4. Labor hours
for accuracy
taken into account) • Identify and implement task improvements and occ. for
and
• Implement and use completeness • Evaluate Ability to Execute Current Overall Maintenance PM,PD,AM
standard prod. Plan Running vs
5. Order
monitoring • Improve Capability and Versatility Non-running
fulfillment
systems • Standardize Improved Maintenance Practices.
rate at crib
• Provide Feedback to Engineering. 5. Confirm AM
3. Materials >95%
5. Unplanned Maintenance Maintenance
• Affordable • Identify and Respond to Crisis. to Standard
Predictive tools • Analyze Crisis.
• Spare Parts • Initiate Short Term Countermeasure
Management PROCESS • Identify Permanent Corrective Action. PROCESS
• Maintenance CONFIRMATION • Execute Corrective Action. CONFIRMATION
Budget • Document Work and Share Lessons Learned.
PROACTIVE PROACTIVE

What needs to be in-place for How do I know What is the work that is required How do I know How can we What is the objective?
the Process to function? the Inputs are to deliver the results? the process is measure success?
delivering delivering
robustly? Page 4 of 7 robustly?

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The Global Ford Production System
Integrated Operating Systems
Operating
System Maintenance Operating System
Maintenance Operating System – Implementation Plan

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The Global Ford Production System
Integrated Operating Systems
Operating
System Maintenance Operating System
MOS – Integration Actions
• Constraint Management; Process standardized and being utilized in
NA Body, Paint, & Final Assy, currently being introduced to FSA, FoE,
and APA
• PM Optimization; PM/Job Plan database & content being scrubbed for
specific items (failure modes, frequencies, labor hours, etc.) and
progress tracked.
 Approximately 80% of FNA database complete
 Additional points of focus to be addressed upon completion of initial tasks

• Spare Parts; Standardized assessment of key assets (Motor &


Gearbox) underway to evaluate…
 Current status of spare parts/inventory in each plant
 Share-the-spare opportunities by region
 Drive standardization of OEM’s, Models, and overall complexity
 Standardized approach to be adapted to other applications
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The Global Ford Production System
Integrated Operating Systems
Operating
System Maintenance Operating System
MOS – Integration Actions (continued)
• Time & Data Management; Eight key activities designated for MOS,
driving participation & ownership of data driven MOS actions at all levels
of the organization
 FPS rollout scheduled for 2Q2012

• Autonomous Maintenance; Standard Visual Job Plan developed (PTO


origin) on high leverage tasks for use by Direct Labor work force
 Clear emphasis on Safety Requirements / Compliance
 High leverage tasks that can be applied/shared across all assembly plants

• FMEA’s / M-task; High leverage OEM / Equipment Job Plans being


optimized for alignment to failure modes, While Running, and use of
Predictive Tools
 Five Primary OEM’s initially (ARO, Bosch, Emhart, Fanuc, SCA Schucker),
ongoing…..
Total Tasks Labor Hrs Rq’d
Pre Scrub 523 tasks 525 hours
Post Scrub 153 tasks 153 hours Page 7 of 7