» There are many simple measures and processes than can be applied to any maintenance operation to reduce costs, which is more beneficial than cost cutting. This can be done by taking a discerning look at the operation to determine where changes and adjustment can be made to increase efficiencies and productivity. Photo courtesy of Peach State Truck Centers APRIL 2017 | VehicleServicePros.com 27 Each Day 1. At the start of the work day, before going into the offi ce, drive around and tour the yard. Take notice of everything: trailers with burned up axles hubs, damaged tires, accident damage, anything that catches your eyes. Get into the weeds. In other words, dig deep into the details. 2. Tour the shop and practice MBWA (management by walking around). Walk around and visit employees, open up dialog, ask questions, truly listen to what they are saying. 3. Tour the parts department. Here again, communicate with the parts people, look at the parts that have been removed and the core and warranty shelves. Pick up a few invoices, check the dates received and dates ordered. Check stocking levels. General Beginnings Th ese steps can help you determine areas ripe for cost reduction. 4. Set up a special visual shelf, in a normal walkway, for all parts removed for inspection or replaced each day. Do the same for cores and warranty removed parts. 5. Set up a parts special order shelf. All special ordered parts should be placed on this shelf. You and your foremen should review this shelf each day. Any parts not installed within 10 days need to be returned. No exceptions. 6. Walk the yard with your managers. Ask them questions, pick their brains, challenge them, ask them about their decisions, tutor and coach them. Leave cell phones in the offi ce so as not to be disturbed. Occasionally, take a technician on a yard walk. 7. Cleanliness. Try and keep your shop looking like an OEM car dealership. A clean, organized workplace saves time and helps boost technician and shop productivity. 8. Organize parts rooms and tire areas for the most effi cient parts, tire management and control. (See Fleet Maintenance May 2016, 24 steps to smarter parts management.) 9. Paint the fl oors with lines and areas of movement. Gloss gray for the shop fl oor; gloss yellow areas for employee and visitor fl ow; gloss red lines between gray and yellow areas visualizing a stop sign; gloss green for areas of safety. Gloss white walls and ceilings make for a clean and bright environment. All areas should have adequate light. 10. Check steel and trash dumpsters to get a snapshot of what is being replaced or wasted. General Mechanical 11. Enhance preventive maintenance (PM) programs by detailing specifi c PM functions. 12. Pressurize the cooling system and cap to 18 to 20 lbs to check for external leaks or internal coolant leaks. Pressure loss and internal leaks are the fi rst sign and early detection of a failed ERG (Exhaust Gas Recirculation) cooler. 13. Battery maintenance. At a PM inspection, remove each cable from battery terminals and load test each battery. No goop, grease or sprays on the terminals, as this could be a cover-up. Besides, no technician likes to clean battery terminals. Grease gunk all over the terminals only increases their displeasure. 14. Steer axle toe-in. Check this at each PM. Not with an alignment machine, but with a simple toe-in bar. Also perform a rear axle check between the two axles for their being parallel. 15. Slack adjuster stroke. Also, at each PM, check the slack adjuster stroke and note this on the PM sheet. No adjusting of automatic slack adjusters (ASA) at a PM or any another time. ASAs “work” or they are worn out. 16. Grease with the best grease available for the vehicle application. Raise the front axle off the ground and lower to the ground for proper greas- Page 30 Make informal visits and listen to employees. » Technician and job inefficiency is a result of disorganized parts and inventory storage. Also organize parts rooms for the most efficient parts management and control. Photo courtesy of DWS Fleet Management Services
FleetMaintenance_April_2017
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