We understand that managing the unforeseeable is hard. Stuff happens. But when operators, quality control, and maintenance work together, the negative impacts can be reduced and overall preventive care can lead to “well-oiled” machines and more predictable outcomes.
It’s better to prevent than fix
With Total Productive Maintenance (TPM) in a box, transfer equipment care to operators and remove the tension between production and maintenance – there’s even a “bat-phone” for when things do go wrong.
Operator Equipment Care
Equipment care is no longer just a maintenance responsibility. With Redzone, factories transfer clean, inspect, and lubricate (CIL) tasks to operators – Ultimately, upskilling operators, freeing up maintenance techs, and preventing unplanned downtime. Digital centerlines ensure one right way to setup and operate the line.
Remove the barrier between production and maintenance with equipment health reports. The health report allows production and maintenance to dig deeper on key reliability items including early defect detection (operator senses), service requests, breakdowns, CILs, and PMs. The interactions promote upskilling of production employees in the care of their equipment.
While prevention is key, the unplanned inevitably happens. Operators call technicians using ‘Uber for maintenance’ to ensure the right information gets to the right person immediately to minimize downtime. For the first time, plants know exactly when a line stopped, when help was requested, when help arrived, and when the line got back up and running.
“The culture has gone from, ‘there’s a maintenance group, there’s a production group and there’s a quality group’ to now we’re all basically one group and we’re all working together.”
Ken CapponiMaintenance Manager
“Redzone gets everybody on your team aligned for the future, so you stop talking about what’s happened in the past. A maintenance breakdown is a maintenance breakdown – that happens. But what do you do moving forward to prevent that breakdown? You call the play in Redzone!”
Corey ArrickSVP Manufacturing
“We have a lot more personal commitment to the equipment from a lot more people now.”
Eric West Snr Dir. Engineering
“What the Reliability module did for us is empower the operators to get directly involved to solve problems as they happened.”
Valentino LascanoPlant Manager
Clean, Inspect, Lubricate
Configurable checks clean, inspect, and lubricate (CIL) can be scheduled based on many different triggers such as beginning-of-shift, calendar day/time, 1,000 hours of runtime, and more.
Multi-media work instructions attached to the checks. Work orders can by automatically triggered off the result of a failed/warned CIL check.
Digitally access the optimal equipment setpoints based on the line or product that can be accessed, updated, or verified during production or at changeovers.
Files or videos linked to the check.
Deviations are automatically recorded and presented in huddles, daily production meetings and in-app historical reporting dashboards.
Identification of abnormal equipment conditions using a visual notification that automatically creates a work order request.
Pictures and videos can be attached for additional context. This can also be integrated with current CMMS.
Preventative maintenance checks that can be configured, triggered, and completed based on frequency, run/down time, or event.
Parts and labor consumption capability is embedded in the check.
One-stop shop to trigger, view, and manage work orders based on a specific location.
Backlog and calendar views will support maintenance planning & scheduling.
Equipment vital signs overview that allows you to manage by exception and prioritize where you need to spend time and resources.
Provides a high-level view of completed operator checks, PMs, and triggered work orders.
Triggers the option to notify maintenance based on the type of line downtime that automatically creates a work order.
Pictures and videos can also be attached for additional context. This can then be integrated with current CMMS.