Slide 1
Nissans Roadmap to Success
475,000 square foot$500M RAV500 employeesCapable of 100,000 vehicles/year19.2M cells/year138M cycles/yearZero Landfill
EVBP MaintenanceLead Eric1
What is the Battery Plant?From a maintenance perspective$500M Maintainable AssetsSold-out Condition12 hour/week scheduled downtimePlus Summer/Christmas shutdowns (1 week per)95% Automated5% material handling and QC1/3 of the plant is inside a clean/dry roomHarsh environment
EVBP MaintenanceLead Eric
2
Who can relate to this type of maintenance program?
EVBP MaintenanceManufacturing - GruMaintenance axProcess Engineering fire hoseQC megaphoneIdeal condition Fire extinguisher3
Phase 1 Understanding the ConditionSelf Assessments
EVBP MaintenanceMaturity MatricesWhere we were4
Maintenance Organization
EVBP MaintenanceLead ChadLooks good right?To be continued5
Planning/SchedulingOne Planner/Scheduler for 61 techniciansPlanning/Scheduling was only being done for one departmentPlanner/Scheduler also had duel responsibilities of handling technicians Master Training Plan
EVBP MaintenanceLead Chad
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CMMS/DataTwo systems being used for data collection (CMMS, Equipment Production System)CMMS not being utilized correctlyCMMS purchased for plant was a PMO toolPMs created by third party contractor not based on any criticality matrix or FMEAsNo usable data from CMMSEquipment Production System functionality issues95% Reactive
EVBP MaintenanceLead Chad7
TrainingTechnicianTraining simulator not being usedNot utilizing the Nissan Training center properlyMaster Training Plan not applicable No Master TrainerContract Trainer not being utilized for trainingSOSs not easily accessible or did not existNo training plan
SalaryNo formalized Asset Management or Reliability training plans
EVBP MaintenanceLead Chad8
Phase 2 Change Management
EVBP MaintenanceRod is external department buy into new maintenance department.Go to next slide9
Change Management
EVBP MaintenanceLead ChadWith new management we needed to be careful about not disenfranchising or discouraging current leadershipRod is external department buy into new maintenance department.No credibility with the other groupsNot wanting to be another flavor of the month
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Phase 3 The Plan
EVBP MaintenanceResonate with anyone?12 hours/week scheduled downtime11
Maintenance Constraints$500M Maintainable AssetsSold-out Condition12 hour/week scheduled downtimePlus Summer/Christmas shutdowns (1 week per)95% Automated5% material handling and QC1/3 of the plant is inside a clean/dry roomHarsh environmentWhats the plan??
EVBP MaintenanceLead Eric
12
Build the Team
EVBP MaintenanceLead ChadHiring REs, moving people into the right spots, etc13
Eric Before RMC Boot Camp and IMC
EVBP MaintenanceEric LeadThis is how I felt after passing CMRP, no direction in sight.yet14
Salary TrainingUT-RMC Boot Camp CMRP CertificationRMIC CertificationR&M Conferences
EVBP MaintenanceLead ChadGot Eric to lead a team up to UT for Boot Camp15
Eric After RMC Boot Camp and IMC
EVBP MaintenanceLead EricThis is us after RMC Boot Camp16
Salary TrainingAsset ManagementCriticality Analysis/FMEAPlanning & SchedulingRoot Cause AnalysisPredictive TechnologiesWhat if we train these people and they leave?What if we train these people and they stay?
EVBP MaintenanceLead EricBrought in outside contractor to lead us through this training17
Technician Training
Assign a Master TrainerTraining policyNew Master Training Plan task list and DatabaseUtilize the Nissan Training CenterFull evaluation on all technicians to establish baselineIndividual training plans for each technician based on evaluationTraining courses to address skill deficiencies
EVBP MaintenanceLead Chad
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Planning/SchedulingPurchased CMMS to met our needsUtilize CMMS properly3 Planners / 1 SchedulerParts KittingPlanning / Scheduling meetings at plant levelCorrect functionality of fault recording system
Plans are worthlessPlanning is everything Dwight D. Eisenhower
EVBP MaintenanceLead Chad19
Phase 4 - Execute
Valley of Disrepair
EVBP MaintenanceEric leadYou need to teach this to everyone that is affected by the change so they know its coming and is natural progression20
Eric Needs Followers
EVBP MaintenanceQuestions?What is the best thing to do when you have a hole in a boat and water is leaking inside? Make another hole to drain the water. Duh!
EVBP Maintenance