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Case Studies

Optimized Spare Parts Management Sets Mine Workshop Standard

A client was looking to achieve optimized spare parts management in its maintenance workshop, which was in an accident-prone condition. Together with YCP Unison, it was looking to achieve an improvement of workshop conditions to maintain order, cleanliness and organization through implementing a standardized, sustainable practice.

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Key Results

Zones in the workshop were assigned specific purposes for streamlined repair workflows
The need for satellite storerooms and accumulation areas were removed allowing instead for more area for repairs
Adherence and buy-in to a new 5S methodology was achieved across offices and workshops to maintain cleanliness and organization

Specific Actions Taken

By collaborating with dedicated working groups selected by the client’s management, YCP Unison’s standard operating procedure to ensure project results were sustained long term included the following:

Implemented the 5S methodology

Provided training across all areas within the maintenance department on this methodology which involved the assignment of zones within each work section

Process Monitoring

YCP Unison worked with client teams to design and implement audit sheets to ensure compliance with the new 5S process, as well as a daily review process.

Ensured Consistency Across Offices

YCP Unison assisted in implementing the initiative in the client’s satellite maintenance shops and maintenance offices. The teams also developed a consistent rating system for employee recognition of the 5S adherence to incentivize continued use of the system and ensure buy-in.

Our Approach

To tackle the disorganization of the client’s workshop, YCP Unison first introduced the 5S methodology. This initiative would be focused not just on cleaning but on ensuring that all parts needed on the floor were accessible, whereas everything that didn’t belong there would be systematically moved to their proper locations.

All parties within the maintenance department took an interest in the initiative and had their respective roles to play. By incorporating the 5S methodology prescribed by Unison, zones in the workshop were assigned specific purposes, and supervisors could better coordinate their roles in keeping the workshop organized. The shop and yard began to grow more organized, removing the need for satellite storerooms and accumulation areas. Instead, these spaces are currently used to prepare for upcoming repairs.

Today, every General Foreman carries out this process daily.

Results

Before implementation of the 5S initiative, the yard was considered a high-risk area because of obstructions due to old tires lying around, garbage cans, and litter everywhere. After implementation, the space is better organized and safer to operate in. Maintenance staff ensure that it remains that way by performing their daily 5S audit daily.

Storage areas are now cleaner, allowing the space is being used correctly, whereas before older unused parts were mixed with parts needed for repairs. The storage areas are now dedicated to storing only the items needed for upcoming repairs.

Everyone in the shop and the maintenance offices participates in keeping the work areas clean, organized, and free of unnecessary items that take up aisle space or clog the aisles: no more hoses and cables, dirty worktables, and oil pans.