Up Time Magazine - December 2008/January 2009 - (Page 21) Task Description Task (Failure Modes __) Original PM Task Change 8 HEPA Filters Optimized PM Tasks Check Magnehelic Gauge (Filter Dirty __) Visually inspect filters via window (Damaged__) (Blown through__) 3 Obj. Inspect. 2 Subj. Inspect. M 12X M 12X 3X 300% Operator Operator 2 2 1R Replace Q 4X HVAC Tech 240 Task Type Freq. (X/Yr) Skill/Craft 1X (Min) Labor Annual (Min) 960 Production Downtime 1X (Min) 300 Annual (Min) 1200 24 24 0 0 0 0 Optimization Results No Crafts Req’d. Reduced 236 Min 98% Reduced 936 Min 97% Reduced 300 Min 100% Reduced 1200 Min 100% Figure 4 - Simple example of an optimized PM task using multiple PM Optimization techniques filters was not included in this example. Added Effectiveness for Greater Reliability At this point we must review the equipment history for indications of failure on functions that should have been protected by the original PM. A failure may indicate that the PM is not fully effective. Although many companies often do not have an accurate formal equipment history documented to an adequate level of detail, an undocumented, informal history usually does exist. This is the history in the experience of the people that have operated & maintained the equipment in the past, including equipment operators, maintenance technicians, engineers, even vendors and contractors. The optimization of the existing PMs for efficiency, combined with failure review, typically provides the optimal results based on current data systems available for PM content and failure recording. While performing the above PM optimization for efficiency to free up labor, invariably additional opportunities for greater effectiveness in the PM are uncovered. These can be anywhere from failure modes on existing components that have not been addressed adequately, to components that have not been addressed at all, to entire functions that have not been included in the PM previously. These are potential failure mode items that can take PM effectiveness to the next level for even greater reliability. Companies are typically identifying from 50-100% additional PM coverage for likely failure modes as compared to the original PMs! Because the added PM tasks are fully optimized during development, the PM efficiency gains are not reduced significantly due to the added PM coverage. For those maintenance organizations that have an existing RCM or FMEA effort in place, analysis of these additional items are an excellent opportunity to partner with these other efforts, making PM Optimization a complementary initiative to www.uptimemagazine.com 21 http://www.sengenuity.com http://www.hawksightglasses.com http://www.hawksightglasses.com http://www.sengenuity.com http://www.uptimemagazine.com
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