Maintenance Technology September 2016 - 88

27 The Challenge To reach this appealing goal without getting mired in the potential difficulties is a challenge, but it is one that can be managed. The solution is to keep it simple and get everyone on the same page. A maintenance only effort-and trying to persuade requestors to comply once it is designed-is an exercise in futility. Therefore, a plant-wide prioritization system has to be developed as a joint effort between maintenance, operations and engineering. Credible representatives from each discipline should be brought in from the start to buy into the concepts and work out the applications, all the way through to implementation. How to Do It We need to start by walking the cross-functional team through the question of "Why should we have a prioritization system?" Then, we integrate their additional observations of how things may work in their specific plant. Next, we begin with a blank slate. We do this even where a system is already in use. We need to ensure that definitions and criteria in the system are still applicable. Too often we've seen where prioritization systems have morphed over time into complex systems of categorization, status and prioritization. So we start with the basics of prioritization. We outline the maintenance department's options for responding to requests. Regardless of what the work is, maintenance can only respond to a request in one of three ways: Frequently, requestors avoid this third priority because experience has shown that it may enter into a "black hole," never to be seen again. Therefore, this priority is accompanied with a commitment as to how long it will take to get the job started. No job will take longer than four weeks to start from when equipment and materials are available. Any job that takes longer than that increases in priority. This commitment is critical to the success of the prioritization system. Prioritization systems begin to come apart when the requests for routine work sit for weeks and months before they are started. We can call these Priority 1, Priority 2, and Priority 3. Keep it simple with "priority" describing urgency. Remember the cost comparisons: Priority 1 and 2 are four to ten times as expensive as Priority 3. That is what maintenance is able to do. These three priorities are how they can respond. Now, it is up to the team to define what conditions justify a specific response. In one case, we were working with a polymerization operations superintendent (a very powerful position in a plastics plant). His name was Roger. He was convinced we could never get it right. He made it clear that if we did not "get it right," he would never follow the system. So we worked with him and walked through each piece of equipment in his operations, discussing the potential condition of each one. We had him tell us what responses he would need for each, given the piece of equipment and its condition. We 1. They can stop what they are doing, close it up, and come immediately. This must start in no more than 24 hours. 2. They can make the request the next job. They finish what they are doing and then insert the request into their weekly schedule, impacting Schedule Attainment. This work must start within two to three days. 3. They can give it to the planner/scheduler to get everything ready and put it on the schedule, allowing it to be planned. WWW.SMRP.ORG 10127-4056 SMRP Solutions SE.indd 27 8/22/16 9:43 AM http://WWW.SMRP.ORG

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
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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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