How Reducing Break Down % ?

Monitor and analyse the cause of the breakdowns....? Then do some thing to minimise any recurring problems. Remember the 80/20 rule....

And concentrate on the problems which are causing the 80% of the faults.

(I reserve the right to be of no help what so ever)

Hello Del The Cat

Thank you for replying i have no idea in rule because i am done electrical diploma in external so no more knowledge in it. so can you explain rule 80/20

Hello there,

Do you know what is causing the breakdowns? My experience is that management often requires solutions before they know the problem. Do you keep statistics? If not, start. Look for the root cause, not the simple cause, i.e, it's not enough to say that lack of lubrication causes bearings to seize - the question is why is it even possible to have a bearing run dry? Then put them in order of %. Start with the biggest and work your down. Quit when you get to 0.5%. Then tell everyone on the team they are all responsible for keeping that number below 0.5% - tie that to their pay raises, good parking spots, comfortable chairs, vacation time, etc.

P.S. learn Del's 80/20 technique. Similar techniques are used by many top notch outfits.

If your breakdown is still high while doing preventive maintenance, you're not doing enough preventive maintenance. Also, as the others have pointed out, eliminating or reducing the occurence of breakdowns is very important.

If a bearing fails after six months, you schedule a replacement every six months. If the failure becomes every four months, you don't just change the schedule to every four months, you find out why the failure has increased in frequency. Then you go and eliminate the cause of the failures. If this is done properly, you may even lengthen the service life of that bearing to a year or two.

The 80/20 rule is not really a rule but a theory and it has numerous variations. It can say that:

• 80% of your downtime comes from 20% of the failures
• 80% of your problems come from 20% of your equipment
• 80% of your results come from 20% of your employees
• 80% of your business come from 20% of your customers
• etc, etc, etc.

If we take your case, if you have five items that causes 100 hours of downtime, 80%, or 80 hours, of the downtime comes from just one of those items.

While not universally true, it is a valid way to think. Take one item that is causing the most downtime in terms of time or cost (or both) and find a way to eliminate or minimize the breakdown. Then your work your way down the list.

'Hope I've explained that better than I think I did.