20th FVI Expert Breakfast

Topic: "Cat and Mouse" – How Production and Maintenance Make Peace.

Guest speaker was Barbara (Lean/TPM Expert), who analyzed the "cold war" in the factory halls. The fronts are clear: Production wants quantity ("runtime"), maintenance wants access ("maintenance").

• The Wall in the Mind: Barbara reported from shop floor meetings. At 8:30 AM, production complains: "The mechanic never comes." At 9:00 AM, maintenance complains: "The operators break everything." Both sides talk about each other, not with each other.
• TPM as a Peace Treaty: "Total Productive Maintenance" (TPM) means: The operator is responsible for the basic condition of their machine (Cleaning = Checking). If they learn to see and report small defects (loose screw, leakage) themselves, they become a "caretaker" rather than just a "driver." This relieves maintenance of minor issues.
• Transparency through Visualization: A simple but ingenious example: A sheet on the machine where it is checked off if the mechanic was there. Suddenly, the perceived truth ("They never come") is disproved by facts.
• Job Rotation Creates Respect: Oliver (practical example) sends trainees to production for 6 weeks. Anyone who has stood on the line for 8 hours and sweated because the machine was acting up repairs it afterward with a whole new level of respect. This breaks down silos.
• Leadership Must Say "Stop": When gossip occurs in meetings, the boss must intervene. Instead of assigning blame ("Who did it?") solutions are needed ("How do we prevent it?").

Context: Technology as a Neutral Mediator

This episode shows that software can improve not only processes but also relationships.

• ADAM as "Single Source of Truth": The dispute "I reported it" vs. "I received nothing" ends when everyone looks at the same system. ADAM documents: When was it reported? When was it responded to? This creates objectivity.
• Autonomous Maintenance 2.0: Barbara spoke of "Cleaning is Checking." ADAM supports this by assisting the operator during cleaning (checklist on tablet/phone). If they see a defect, they take a photo. This significantly lowers the barrier for TPM.
• Knowledge Transfer: When maintenance provides the operator with "One Point Lessons" (short guides) via ADAM, the operator can fix small disruptions themselves without waiting for the mechanic. This increases OEE and satisfaction on both sides.

Conclusion: The key to peace is shared responsibility. ADAM gives both sides the tools to take on this responsibility without blocking each other.