Maintenance Technology September 2016 - 33
RELIABILITY STRATEGIES
Table I. Strategic Plan for a Typical Reliability-Improvement Initiative
Strategy
Change the
organization
(Short/long term)
Objectives
Plan
Goals Yr. 1
Goals Yr. 2
■ Establish a reliability
function at the site.
■ Hire a reliability engineer.
■ Deliver higher levels of
proactive asset care.
■ Dedicate mechanics to preventive and predictive care.
25% critical
assets with
care plans
50% critical
assets with
care plans
Top 3 to 5
identified
Top 3
eliminated
25% standard
work
50% standard
work
Operator rounds
started
Operators
performing PMs
Transitions
reduced by 50%
Transitions
reduced
by 75%
■ Establish asset care for critical equipment.
Eliminate failure
(Short term)
■ Remediate site's top three bad actors.
Ensure execution
of proactive work
(Long term)
■ Complete higher levels of proactive
work on the schedule.
■ Identify top causes of failure.
■ Identify actions to eliminate.
■ Revise the maintenance work process.
■ Create standards for planning and scheduling.
■ Create more standard work.
Develop operator
ownership
(Short/long term)
■ Implement operator-driven
reliability (ODR) program.
■ Train operators on equipment care.
■ Revise operating instructions.
■ Convert some PMs for operators.
Reduce transition
times (Long term)
■ Apply lean manufacturing principles to
reduce transition times.
■ Analyze product transitions.
Improve productionline performance
(Long term)
■ Develop a long-term capitalimprovement program for the site.
■ Begin to implement total productive maintenance (TPM).
■ Lean the process and remove barriers.
■ Evaluate asset condition and performance.
■ Dedicate lines to high volume products.
■ Capital plan
in place
■ Justify automation and asset replacement
for higher-speed processing.
■ Realigned
product lines
■ Align product-line volumes with line capacities.
New highspeed line
in place
This table lays out a reliability-improvement plan that should produce tangible results in two years.
1. Ensuring that all critical assets
have the appropriate care should
be high on the priority list. This
can be accomplished as defects
arise and through tools such as
Pareto and root-cause analyses.
There's no sense in revising care
for equipment that hasn't shown a
long history of failure. Evaluating
work history and having a trigger
system to identify what to work
on is crucial.
2. Maintenance and reliability
work processes must then be
modified or built and "tied"
together. This means that workhistory analysis and planning
and scheduling should be a focus.
Those steps are how these two
work processes come together.
Remember that reliability designs
asset care and is strategic in
nature while maintenance is
tactical and executes care. Work
history provides information to
the reliability process to revise
care to prevent future failure.
Planning and scheduling ensures
that the care tasks designed by the
SEPTEMBER 2016
reliability function actually are
executed by maintenance.
Impatience
and a desire by
management
to see the results
of improved
reliability seem to
go hand in hand.
3. Competencies must be evaluated
for the existing workforce and
new hires. Competency descriptions for maintenance, reliability,
and operators, and any new job
descriptions need to be created.
New hires should be evaluated
against these requirements. Staff
training should be obtained
through sources such as plant
trainers, community colleges,
third-party consultants, and
vendors. A long-term goal for
certification is also a way to create
a "pull" for knowledge for the staff
and provide incentives for career
development.
4. Finally, programs for lubrication, predictive analysis,
stocking critical parts, precision
work, and stores management (to name a few) can be
implemented over the long
term. Appropriate sectors of each
organization, i.e., operations,
procurement, engineering, and
maintenance, should take responsibility for selected elements.
Lubrication should always top
the list. Without good lubrication
practices, the remaining reliability
elements cannot be effective.
Note that these details represent
just one way to pace a reliability
program. Many variations exist,
depending on the strengths and
weaknesses of an organization.
Whether your site relies on in-house
staff or work with a consultant, never
jump into a plan without some form
of conditional assessment. Since
MAINTENANCETECHNOLOGY.COM | 33
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Table of Contents for the Digital Edition of Maintenance Technology September 2016
Editorial
Uptime
On The Floor
Old-School Approach To New-World Technology
Art Meets Reliability Science
Commit To Safety
Robot-Human Interaction Getting Safer
Sanitary, Stainless Conveyors Not The Same
Reduce Hidden Process-Safety Costs
Pace Your Reliability Program
Win The War With 'Lubrication By Design'
SAP Tips And Tricks
Understand Pump Vibration
Select The Right Relay
Bearing Care
Clear Up HOA Confusion
Potato Waste Becomes Clean Water, Energy
Products
Showcase
Ad Index
Final Thought
Maintenance Technology September 2016 - 1
Maintenance Technology September 2016 - Cover1
Maintenance Technology September 2016 - Cover2
Maintenance Technology September 2016 - 1
Maintenance Technology September 2016 - 2
Maintenance Technology September 2016 - 3
Maintenance Technology September 2016 - Editorial
Maintenance Technology September 2016 - 5
Maintenance Technology September 2016 - Uptime
Maintenance Technology September 2016 - 7
Maintenance Technology September 2016 - On The Floor
Maintenance Technology September 2016 - 9
Maintenance Technology September 2016 - Old-School Approach To New-World Technology
Maintenance Technology September 2016 - 11
Maintenance Technology September 2016 - 12
Maintenance Technology September 2016 - 13
Maintenance Technology September 2016 - 14
Maintenance Technology September 2016 - 15
Maintenance Technology September 2016 - Art Meets Reliability Science
Maintenance Technology September 2016 - 17
Maintenance Technology September 2016 - 18
Maintenance Technology September 2016 - 19
Maintenance Technology September 2016 - Commit To Safety
Maintenance Technology September 2016 - 21
Maintenance Technology September 2016 - 22
Maintenance Technology September 2016 - 23
Maintenance Technology September 2016 - Robot-Human Interaction Getting Safer
Maintenance Technology September 2016 - 25
Maintenance Technology September 2016 - Sanitary, Stainless Conveyors Not The Same
Maintenance Technology September 2016 - 27
Maintenance Technology September 2016 - 28
Maintenance Technology September 2016 - Reduce Hidden Process-Safety Costs
Maintenance Technology September 2016 - 30
Maintenance Technology September 2016 - Pace Your Reliability Program
Maintenance Technology September 2016 - 32
Maintenance Technology September 2016 - 33
Maintenance Technology September 2016 - 34
Maintenance Technology September 2016 - 35
Maintenance Technology September 2016 - Win The War With 'Lubrication By Design'
Maintenance Technology September 2016 - 37
Maintenance Technology September 2016 - 38
Maintenance Technology September 2016 - SAP Tips And Tricks
Maintenance Technology September 2016 - Understand Pump Vibration
Maintenance Technology September 2016 - Select The Right Relay
Maintenance Technology September 2016 - Bearing Care
Maintenance Technology September 2016 - 43
Maintenance Technology September 2016 - Clear Up HOA Confusion
Maintenance Technology September 2016 - Potato Waste Becomes Clean Water, Energy
Maintenance Technology September 2016 - 46
Maintenance Technology September 2016 - 47
Maintenance Technology September 2016 - 48
Maintenance Technology September 2016 - 49
Maintenance Technology September 2016 - 50
Maintenance Technology September 2016 - 51
Maintenance Technology September 2016 - 52
Maintenance Technology September 2016 - Showcase
Maintenance Technology September 2016 - Ad Index
Maintenance Technology September 2016 - 55
Maintenance Technology September 2016 - Final Thought
Maintenance Technology September 2016 - Cover3
Maintenance Technology September 2016 - Cover4
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