EARLY EQUIPMENT

MANAGEMENT

WCM EEM
ALIGNMENT
2

UNILEVER, WCM/EEM UEnS

PROJECT MANAGEMENT PHASES
The following graphics show how the phases of
each overlap. Basis for the overall alignment.
WCM/EEM
Basic
Design

Planning

Detailed
Design

Installation Trials

Manufacture

Initial Flow

UEnS
Post Project
Reviews

Product
Qualifcatio
n

Commissioning

Precommissionin
g

Installatio
n

Training

Equipment
Acceptance

Equipment
Construction

Procuremen
t

Detailed
Design

Contrac
t

Front End
Engineerin
g

Conceptual
Engineerin
g

Feasibility

Initiatio
n

UEnS PM PROPOSED
METHODOLOGY
The Unilever UEnS PM Methodology uses the 7
8

steps of WCM as its basis while incorporating EEM

Project Gates at critical points
Project Closure
7

WCM Steps

Post Project Reviews

Production Qualification

Step 1: Planning
6

Step 2: Basic Design

Commissioning

Step 3: Detailed Design

Pre-Commissioning
Installation

Step 4: Manufacture
Step 5: Installation
5

Step 6: Production Trials

Step 7: Initial Flow
Project Gate

Training
Equipment Acceptance
Construction/Testing
Procurement

Detailed Design
Grey text = Step OUTPUT

Contract
3

Front-end Engineering

Conceptual Engineering

Feasibility
Initiation

KEY WCM
APPROACH
6

KEY COMPONENTS OF WCM EEM

Cross Functional Team
Front Loading Concept
Life Cycle Costing
MP Info
7 Functional Design Elements
Design Review Check lists
Process FMEA
Layout to reduce NVAA
Machine Ledger generation

FRONT
LOADING
8

TWO WAYS TO FIX PROBLEMS | THE

EASY WAY..AND THE HARD WAY
Our Ability to Fix
a Problem as a
Project
Progresses

The Cost to Fix

a Problem as a
Project
Progresses

Project
Schedule

Cost

Project cost and project lead time with and without

EEM
Cost difference with and without EEM

Lead time difference with and

without EEM

Detail checking by front

loading concept requires
longer time at early stages
but less time at later stages

3
2
1

6
7
Copex process

10
Time

LIFE CYCLE
COST
11

LIFE CYCLE COST CONCEPT

The traditional approach to chose between equipment
suppliers is generally based on the initial investment.
WCM approach requires a different method: equipment must
be inexpensive, not only in terms of the initial investment
but also in terms of its running costs that will be faced
during the whole life cycle of the machine.
LCC = IC (Initial Cost) + RC (Running Cost)
% of cost during different phases

Having higher costs in the frst

phase leads to reducing the
overall cost.
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LCC TEMPLATE - UENS

13

LCC EXAMPLE (2)

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MP INFO

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MP INFO
The lessons learned in the past feed into the
Maintenance Prevention Info and ultimately into Core
Design.
MP Info and adherence to Core Design will impact on:
Availability
Maintainability
Operability
Safety / Environment
Quality
Cost

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FUNCTIONAL
DESIGN

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MP FUNCTIONAL DESIGN

Checklists are needed at each step to verify the

respect of the 7 design points above.
Design reviews have to be performed by use of
checklists
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CHECKLISTS AND THE

IMPROVEMENT PROCESS

Checklist
Database

Checklists have to be used to improve the system

Checklists are continually updated and strengthened by
experience of error detection
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20

ERROR PREVENTION
Errors are the causes of defects!

Unfortunately, it is impossible to
eliminate all the errors from all
human activities. Errors due to
distraction are possible and
inevitable. But errors will not be
transformed into defects if
feedback exists and corrective
measures are applied at the
origin of the defect.

POKA YOKE is a tool to prevent human

errors during manufacturing operations
It is a preventative technique used to
prevent errors or highlight one when it
occurs

POKA YOKE

POKA = Mistake, YOKE = Avoid

The POKA YOKA are easy
technical devices that prevent
defects that occur
POKA YOKE allows to prevent
potential route causes such
as:Mistakes
Lapses
Replacement
Wrong Readings
Wrong Assembly
Etc..............

The logic is based on Zero Defect

Approach This can only be achieved by
preventing errors, not correcting them
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POKA YOKE EXAMPLE (1)

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POKA YOKE EXAMPLE (2)

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EEM FUNCTIONAL DESIGN SAFETY

Safety Design
Providing a safe work area without causing the
sense of fatigue and non deteriorating.
Requirements
Avoid protrusions or anything that could hook
Avoid risk of stumbling (piping and wiring
management)
Avoid unnatural working postures
Avoid vibration, noise, odours, heat and darkness

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27

EEM FUNCTIONAL DESIGN RELIABILITY

Reliability Design
Preventing equipment function deterioration and
equipment function stoppage (High MTBF)
Requirements
Low frequency of failures
Low frequency of minor stoppages
Low frequency of quality defects
Set Up and adjustment not required
Stability of machine cycle time
Set conditions do not change easily
Functions to notify of failures provided
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EEM FUNCTIONAL DESIGN MAINTAINABILITY

Maintainability Design
Easiness in measuring deterioration, failure
fnding and restoration (Low MTTR)
Requirements
Quickness in fnding failed components
Quickness in fnding deteriorated components
Ease of understanding fluctuations of set conditions
Ease of replacing parts
All parts are easy to maintain
High skilled work not required
Ease of obtaining spare parts
Ease of oiling and replacing oil
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30

EEM FUNCTIONAL DESIGN AM

AM Design
Design of the equipment to allow operators to
quickly and easily perform maintenance
activities such as cleaning, lubricating and
checking
Requirements
Elimination of sources of leakage
Localised dust collection
Installation of covers to protect scattering
Better means for cleaning and lubrication
Centralised lubrication
Installation of inspection windows
Orderly arrangement or wiring and piping
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32

EEM FUNCTIONAL DESIGN OPERABILITY

Operability Design
Enabling right operation quickly and correctly in
equipment operation, set up and adjustment
Requirements
Easy set up and adjustments
Operating buttons (limited number)
Operating procedures can be visually understood
Easy to return to basic condition after problems

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EEM FUNCTIONAL DESIGN DIAGNOSIS

Diagnosis Design
Easy to check the condition of the equipment
Requirements
Trouble shooting for failures
Trouble shooting for minor stops

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MACHINE
LEDGER
36

MACHINE LEDGER

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MACHINE LEDGER TO COMPONENT

LEVEL

Machine Ledger

38

MACHINE LEDGER TO COMPONENT

LEVEL

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THE END
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