Efficient Plant May 2018 - 11

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feature | maintenance processes

STEP 1, IDENTIFICATION: The maintenance-

STEP 2, AUTHORIZATION: Work authorization

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is a crucial but, sometimes, complicated part of a
maintenance process. That's because companies

often impose barriers that prevent shift personnel

work-identification step begins with an observation,

from making maintenance-approval decisions. In

usually by a machine operator who documents an

such cases, the repair is delayed until someone with

asset malfunction. The operator should first diagnose
the problem. Diagnostic activities include comparing
normal operation to current abnormal operation.
Operators have typically used their senses,

i.e., sight, sound, and feel, to identify and assess

malfunctioning equipment. Today, though, sensors
are used extensively to discern malfunctions

the requisite approval level makes the decision-which can

unnecessarily extend downtime.

Sadly, it's still not unusual to find well-intentioned financial barriers

that add cost and contribute to poor decision-making in today's plant
operations. Although not as bad as it was in past decades, obsession
with maintenance cost is still a problem.

If repairs are delayed until someone authorizes the expenditure of

at levels undetectable to humans. As a result, a

funds, production throughput is detrimentally affected. Shop floor

environments is getting field operators to check

they are not, they will likely make temporary repairs, and the process will

common problem in highly automated manufacturing
their equipment. All too often, they rely on

instrumentation and alarms to make them aware of

personnel should be authorized to make an effective permanent repair. If
inevitably repeat itself in the not-too-distant future.

In some cases, decisions can involve multiple levels of management,

abnormalities. To counter this cultural issue, many

resulting in authorization by committee. Such short sightedness not

devices when making their rounds. Bar codes or

who know what to do. Once denied the trust to make repair decisions,

organizations require operators to use hand-held

RF devices attached to the equipment are used to
ensure on-site inspection is conducted.

Included in work identification is some form of

only increases downtime, it demoralizes those closest to the equipment
operators will naturally reject any attempt to hold them accountable for
equipment performance.

diagnostic analysis. Thus, operators must be trained
in troubleshooting techniques. Once operators

diagnose problems, they must determine whether

they have the skills and tools necessary to effect a
repair.

As is often said, operators are the first line of

defense against unplanned failures. If they can

successfully perform and complete a repair, costly

STEP 3, PLANNING: While maintenance planning

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has been around for more than a 100 years, far

too many sites fail to do this step well. Lacking a
disciplined approach to maintenance planning,

they are basically forced to recreate a job plan

downtime and unnecessary maintenance can

be avoided. If they can't, it's essential that they

accurately document their findings for the benefit

every time a repair is needed.

Over time, every maintenance job will be repeated.

Failing to store detailed maintenance job plans so they

of those who follow. This is especially critical in

can be easily found and retrieved not only affects scheduled repairs,

typically work the day shift. If operators don't

invaluable repair-procedure information, resulting in wasted time and

24-hr. shift operations where maintenance personnel
capture their findings with sufficient granularity, it

will be up to maintenance teams to do so-and they

it prevents front-line supervisors and craft personnel from accessing
inefficiency.

No matter how skilled or experienced, maintenance-craft personnel

won't be able to leverage what the operators may

should follow defined job plans and repair procedures. Given the fact

symptoms. Those types of observations can be

made to lessen the likelihood of error. Job plans should include labor and

have observed in the way of important pre-failure
invaluable in root-cause analysis.

MAY 2018

that humans are prone to mistakes, every reasonable effort must be
material requirements, including the craft, hours, required parts.

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Table of Contents for the Digital Edition of Efficient Plant May 2018
