Administrative, behavioral, and work process changes for reliability imporvements in pelletizer rubber pull rollers used in manufacturing of engineere

Abstract

This project focuses on improving work practice around pelletizer equipment for the purpose of reducing business impact from maintenance costs. There is a particular emphasis on the human behavior factor influencing the resistance to change. This issue has parallel application to a variety of change management efforts in manufacturing or process improvement environments. The study introduces pelletizer equipment and the standard approaches taken by three units - or "plants" - within one particular chemical manufacturing facility (which remains nameless for anonymity), for pelletizer pull roll maintenance. The impact of poor practices results in significant business impact, especially over the life of the facility. The focus of the study is implementing best practice changes in each of the three units to alter human behavior around rubber pull roll maintenance, and introduce sustainable changes that will result in a recovery of the expense of the pull rolls. Each unit has its own set of unique challenges that must be overcome to have a positive impact. As part of this study, trials were conducted and documented with positive results. Administrative and behavioral changes were an integral part of the change management process. At the conclusion of the project, each unit has a solid foundation for a path forward to sustainable and meaningful change that improves business cost and efficiency long term.