Improvement actions: Leadec's solutions

The challenge: High cost of replacement of electronic boards for various equipment in addition to the possible unavailability of spare parts in stock, delaying the execution of necessary maintenance, or even high volume of boards in stock

The solution: The repair of electronic boards through the implementation of electronics and automation laboratories in Leadec’s main operational units. Electronic technical and PLC programming training to designated Leadec employees.

The results:

• Savings of up to 70% compared to the purchase of new components
• 40% reduction in the backlog due to lack of replacement components
• 25% reduction in inventory value for electronic components
• Technical development of the Leadec teams involved in the program

The challenge: Premature saturation of filter elements (bag type) in relation to planned period; `cost increase with purchase of filtering elements beyond what was scheduled; increased unplanned maintenance activities

The solution: Design and installation of flat-type pre-filters before bag-type filters, preserving equipment’s operating, flow and load characteristics, with a replacement interval of 3 months

The results:

• Reduction of replacement interval of main filters (bag type) from 3 to 12 months
• 55% savings in the purchase of filter elements considering the additional replacements related to pre-filters
• Reduced frequency of unplanned interventions

The challenge: Improve preventive maintenance performance and reduce corrective interventions on equipment, batteries and accessories; reduce maintenance costs per equipment and offer greater transparency in the maintenance and delivery process

The solution: Introduction of Leadec Equipment Maintenance Management System; adoption of dedicated work team 24/7; use of data extraction software from the equipment manufacturer and use of the benchmarking with Leadec reference activitites in another business unit

The results:

• Increase of 215% in execution of scheduled preventive maintenance
• Reduction of 60% in corrective interventions
• Complete maintenance report on each delivery
• Daily update of the record in the customer's system
• Reduction of ≈ 35% in the total cost of maintenance of equipment and batteries & inclusion of other activities in the scope of service

The challenge: Excessive occupational exposure to flammable liquid, uncomfortable application methodology for employees and excessive use of solvents to carry out activities.

The solution: Changing the supply and application procedure using appropriate containers and sprayers. Division of activities and training for specific activities.

The results:

• 50% reduction in the teams’ occupational exposure to flammable liquid
• Greater comfort when performing application and cleaning activities
• 67% reduction in the consumption of solvents to carry out the activity

This measure also provided the following indirect results:

• Optimization of other activities related to technical cleaning in the area
• 40% reduction in the consumption of fabric used in the activity
• 50% increase in the useful life of the main PPE used in the execution of the main activity
• Reduction in the volume of water used in the cleaning process and, consequently, a reduction in the treatment’s  environmental impact