Shop floor excellence audit
A shop floor excellence audit is used to check the effectiveness of the maintenance team in keeping the machine in basic condition. The best way to evaluate this is to use the daily running inspection checklist as audit criteria.
One of the most important tools I initiated and utilized as a maintenance engineer is the daily runtime shop floor excellence audit. As simple as it may be, it is the most useful runtime for just-in-time detection of anomalies on any equipment. The template covers every machine per line with specific questions addressing critical components responsible for sustaining safety, quality, and reliability.
The audit template questions require yes-or-no answers, readings, ranges, and observations from machine operators. The audit is carried out by the technicians on duty as a daily runtime check for any running line. The process takes between 0.5 and 1 hour to complete the inspections on all equipment on the line. This time can vary depending on the number of minor interventions by the technician during the process, the number of machines, and the length of the checklist.
After this daily checklist routine, the next item on the planned maintenance agenda is the daily planning meeting. During this meeting, the technicians are given room to escalate their observations for proper planning and documentation, while the maintenance planner keeps track of the audit to ensure that it is done on a daily basis. The checklist is inputted into the Excel version to generate the shop floor excellence score for the line.
This becomes a very useful performance index for the maintenance department. It also provides an avenue for daily and early interaction between the maintenance team and the production team. This is particularly important because the operators have more interactions with the machine and can easily observe any changes in the operating condition, such as increased vibration, abnormal noise, frequency of intervention, etc.
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