Chuck Yung
Senior Technical Support Specialist
Electrical Apparatus Service Association
St. Louis, MO
The paper "Little Things That Make a Big Difference in the Service Center" by Chuck Yung, presented at the EASA Convention 2017, explores various practical tips and strategies to enhance efficiency, productivity, and employee satisfaction in service centers. Yung emphasizes that small improvements can yield significant benefits without requiring substantial investments.
One key area for improvement is workstations. Yung suggests using interlocking cushioned floor pads in areas where technicians spend a lot of time standing, which can reduce strain and improve comfort. He also recommends comparing workstations to identify efficient setups and encouraging productive employees to share their tips.
Training and education are highlighted as essential for improving quality and reducing mistakes. Yung advises taking advantage of EASA's webinar series, creating a library in the break room with work-related information, and using YouTube videos to educate employees about electric motors.
The importance of a well-equipped break room is discussed, including tables, chairs, a refrigerator, microwave, oven, and sink. Yung also addresses the potential benefits and pitfalls of a suggestion box, emphasizing the need for management to take suggestions seriously and provide feedback.
Innovation is encouraged, with Yung sharing examples of service centers that have implemented unique ideas, such as exercise rooms to improve employee health and reduce insurance costs, and specialized equipment for handling large stators.
Attitude and productivity are linked to billing practices, with Yung advocating for continuous billing rather than end-of-month billing to improve profit margins and reduce non-billable overtime. Flex time and overlapping shifts are suggested to accommodate employees' needs and improve morale.
Service center equipment is another focus, with recommendations for improving lighting, using clear plastic weather strips for bay doors, and optimizing floor space under cranes. Yung suggests relocating equipment that doesn't require crane access and using roller conveyors and transfer carts to move parts efficiently.
Overhead cranes and jib cranes are discussed as potential bottlenecks, with suggestions for adding a second trolley, using forklifts or pallet jacks, and installing jib cranes in areas that monopolize crane time. Yung also highlights the importance of proper rotor handling and testing, using rotor lifters, rotor flats, and magnetic imaging paper.
Cleaning and disassembly tips include using automatic parts washers, refillable spray atomizers, and vertical stands for shafts. Yung advises using burnout ovens for cleaning end brackets and attaching metal pigeon tags to leads for identification.
In the winding department, Yung recommends pneumatic hammers for reducing core losses, accurate scales for weighing wire, semi-automated winding machines, and foot shears for cutting insulation. He also suggests enclosed lead wire carts and dedicated test panels for the winding department.
For winding treatment, Yung advises preheating windings, establishing clear rules for draining stators, and using removable drip trays on bake oven carts. He also recommends using kraft paper to cover work surfaces and squeegees for cleaning stator bores.
In the machine shop, Yung suggests using prefabricated housing sleeves, dry ice for shrinking parts, and profilometers for evaluating commutator runout. He also recommends using full-page magnifiers to reduce eye strain when machining commutators.
Storage tips include organizing parts storage with labeled pallet racks and color-coded tags for specific departments. Yung also discusses the benefits of off-site storage for customers' motors and the potential for green business practices with wind turbines or solar arrays.
Finally, Yung provides miscellaneous time-saving tips, such as portable key mills, garage door rollers for dummy rotors, and digital cameras for documenting work. He concludes by emphasizing the importance of continuous improvement and innovation in service centers.
Key Points Covered:
- Improving workstations with cushioned floor pads
- Enhancing training and education through webinars, libraries, and videos
- Importance of a well-equipped break room
- Benefits and pitfalls of suggestion boxes
- Encouraging innovation and unique ideas
- Continuous billing practices to improve profit margins
- Flex time and overlapping shifts for employee morale
- Optimizing service center equipment and floor space
- Addressing overhead crane and jib crane bottlenecks
- Proper rotor handling and testing techniques
- Cleaning and disassembly tips
- Recommendations for the winding department and winding treatment
- Machine shop tips for machining and evaluating parts
- Organizing parts storage and off-site storage benefits
- Green business practices with wind turbines and solar arrays
- Miscellaneous time-saving tips
Key Takeaways:
- Small improvements can yield significant benefits in service centers.
- Enhancing workstations, training, and break rooms can improve employee satisfaction and productivity.
- Continuous billing practices and flex time can improve profit margins and morale.
- Optimizing equipment and floor space can reduce bottlenecks and improve efficiency.
- Proper rotor handling, cleaning, and disassembly techniques are essential for quality repairs.
- Investing in semi-automated winding machines and accurate scales can save time and reduce errors.
- Organizing parts storage and considering off-site storage can streamline operations.
- Green business practices can enhance the company's image and appeal to customers.
- Continuous improvement and innovation are key to success in service centers.
Related Reference and Training Materials
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