Through our 3T SOP model, you gain in-depth knowledge about how your business processes and systems need to work. You get control of each action and make informed decisions followed by timely delivery of products or projects.
To make process tracking and management easier, our experts, after extensive research and analysis, follow the 3TSOP model. The 3Ts are defined as Test, Tolerance, and Target. The idea of 3T SOP is to come up with a deeper way of how a process or a system needs to work.
In case of a business, when we are trying to improve the OEE of a machine by performing conditional monitoring, conditional maintenance and preventive maintenance to eradicate the breakdowns, we begin with the principle of prioritizing. We prioritize those black holes in your process which will lead to the most significant financial impact for the business in case a change is to be implemented.
In the process of prioritization, we initially target Critical Constraint Machine (CCM) in the entire value – chain. We do so by identifying the equipment having the lowest output in comparison to other machines that are responsible for processing the material. Through CCM, we define the final output of your plant.
We then carry out a critical analysis which involves ascertaining how the above-listed factors are going to affect the final output.
Followed by the CCM identification, we prioritize the collection of data that tells us the types, frequencies, and impact of breakdowns on the CCM.
Once the impacts of the breakdown have been identified, we study the production process from the start -to- end usually by means of video filming. We then understand the flow of work that the users practice in order to deal with the breakdowns in such processes.
Cleaning, Lubrication, Re-tightening, Inspection (CLRI) – The first thing that can be done without the need to make hefty expenditure is to maintain the environment around the machine. We can control the environment by standardly cleaning the machine at a certain frequency and stipulated interims. We define a 3T SOP for this approach. Meaning, that the test, tolerance, and targets for every activity in CLRI are defined. Subsequently, the people are made to understand and trained to perform steps as defined in the 3T SOP. Eventually, it is ensured that they perform the same on a regular basis parallelly tracking the performance of the machine (i.e., if the breakdowns are reducing and OEE is improving). This approach is suitable for marginal OEE improvement (let’s say from 55 to 70 percent).
Preventive Maintenance - For the next level OEE improvement (let’s say from 70 to 85), the approach requires deeper invasion and maintenance of the machine. At the same time, we also figure out potential design flaws. However, that requires automation. In order to perform the maintenance, we begin with prioritization once again. Doing so, we are able to figure out which part inside the machine is malfunctioning and at what rate.
Once the prioritization has been set, we devise 3T SOP for Preventive Maintenance. Preventive Maintenance includes de-assembling of the machine, figuring out the potential wear and tear and eventually repairing or replacing the faulty parts. The 3T SOP thus devised helps us in eradicating the breakdowns at the potential to failure stage dramatically improving the OEE. It does so by specifying the indicators of breakdown and specifying what steps of maintenance are to be performed in accordance.
We keep refining the 3T SOPs by taking into consideration the design flaws of equipment and work on improving the same. Doing this improves the performance, quality, and availability of the machines. This ultimately maximizes the OEE of the plant.
If you want to contact us for your plant process analysis, you can reach us anytime.