Maintenance Technology April 2015 - (Page 31)

RELIABILITY STRATEGIES By Wayne Vaughn, CMRP PCA Consulting IT'S A FACT OF LIFE across industry: Many organizations need to upgrade their basic maintenance practices. Even when good ones are in place-such as preventive and predictive programs, effective planning, scheduling and MRO-purchasing/storeroom policies-some plants still need to strengthen elements like equipment availability and cost-reduction efforts. Improving availability and reducing costs (from both maintenance and operational standpoints) can best be approached by implementing an equipmentreliability-improvement program. While these efforts may require significant time and resources to implement, they can generate enormous returns. Getting the biggest reliabilityimprovement bang for your buck calls for careful, upfront planning: Success involves more than simply hiring engineers and telling them to go out and "fix reliability." Start with your data While the fact that data drives reliability improvement may seem obvious, it's not uncommon for companies to either 1) not have data; or 2) have data that's not easily mined from their CMMS/ EAM systems. The following activities are crucial to undertake prior to embarking on a reliabilityimprovement initiative: ■ Ensure you have best-practice work processes that collect data and appropriate policies in place. ■ Ensure that you classify work in a way that it can be mined to understand problems. ■ Identify key performance indicators (KPIs) that can point to potential opportunities. ■ Establish KPIs to gauge how well your preventive (PM) and predictive (PdM) programs perform. Best-practice work processes The work-order work process is the most fundamental element of successful maintenance. All work must be captured. This must include labor, materials, contractors and other expenses that go into maintaining plant equipment. This information must be accurate, and the type of work being done must be coded carefully. A second key area is ensuring that all work goes through a planning and scheduling process so that needed work is agreed to by operations and executed systematically. This means all PM and PdM work will go through this process. (KPIs and effective management-review procedures must be in place to make sure these important processes are accomplished effectively.) While an entire book could be written about these basics, this article focuses on PM and PdM work orders. Companies spend time to write PM instructions and create PM programs, but often don't manage the process effectively. It is important that PM efforts find and repair things that will prevent operational outages or other emergency situations. A good way to do this is to ensure that when something is found, a work order is created to do that corrective work. Too often, companies allow technicians to repair found defects and charge their time and materials to PM work orders. This is a big mistake, and indicative of an area where a policy must be in place. Although this can seem a pragmatic way to perform work that might involve only a few minutes of a technician's time, it's one that could potentially mask a problem. A good policy is to establish a timeframe for such work, say 15 minutes. Work that can't be performed within the specified time would require a follow-up work order. It's also important that the follow-up work order be appropriately coded as work identified by a PM activity. An additional recommended policy element is that, regardless of time, if a part is required for the repair, a corrective-action work order must be created The path to success involves more than simply hiring engineers and telling them to go out and 'fix reliability.' APRIL 2015 MAINTENANCETECHNOLOGY.COM | 31 http://www.MAINTENANCETECHNOLOGY.COM

Maintenance Technology April 2015

Table of Contents for the Digital Edition of Maintenance Technology April 2015

Maintenance Technology April 2015 - Cover1
Maintenance Technology April 2015 - Cover2
Maintenance Technology April 2015 - 1
Maintenance Technology April 2015 - 2
Maintenance Technology April 2015 - 3
Maintenance Technology April 2015 - 4
Maintenance Technology April 2015 - 5
Maintenance Technology April 2015 - 6
Maintenance Technology April 2015 - 7
Maintenance Technology April 2015 - 8
Maintenance Technology April 2015 - 9
Maintenance Technology April 2015 - 10
Maintenance Technology April 2015 - 11
Maintenance Technology April 2015 - 12
Maintenance Technology April 2015 - 13
Maintenance Technology April 2015 - 14
Maintenance Technology April 2015 - 15
Maintenance Technology April 2015 - 16
Maintenance Technology April 2015 - 17
Maintenance Technology April 2015 - 18
Maintenance Technology April 2015 - 19
Maintenance Technology April 2015 - 20
Maintenance Technology April 2015 - 21
Maintenance Technology April 2015 - 22
Maintenance Technology April 2015 - 23
Maintenance Technology April 2015 - 24
Maintenance Technology April 2015 - 25
Maintenance Technology April 2015 - 26
Maintenance Technology April 2015 - 27
Maintenance Technology April 2015 - 28
Maintenance Technology April 2015 - 29
Maintenance Technology April 2015 - 30
Maintenance Technology April 2015 - 31
Maintenance Technology April 2015 - 32
Maintenance Technology April 2015 - 33
Maintenance Technology April 2015 - 34
Maintenance Technology April 2015 - 35
Maintenance Technology April 2015 - 36
Maintenance Technology April 2015 - 37
Maintenance Technology April 2015 - 38
Maintenance Technology April 2015 - 39
Maintenance Technology April 2015 - 40
Maintenance Technology April 2015 - 41
Maintenance Technology April 2015 - 42
Maintenance Technology April 2015 - 43
Maintenance Technology April 2015 - 44
Maintenance Technology April 2015 - 45
Maintenance Technology April 2015 - 46
Maintenance Technology April 2015 - 47
Maintenance Technology April 2015 - 48
Maintenance Technology April 2015 - Cover3
Maintenance Technology April 2015 - Cover4
Maintenance Technology April 2015 - 53
Maintenance Technology April 2015 - 54
Maintenance Technology April 2015 - 55
Maintenance Technology April 2015 - 56
https://www.nxtbook.com/atp/MaintenanceTechnology/efficient-plant-june-2021
https://www.nxtbook.com/atp/MaintenanceTechnology/epapril2021
https://www.nxtbook.com/atp/MaintenanceTechnology/epmarch2021
https://www.nxtbook.com/atp/MaintenanceTechnology/epjanfeb2021
https://www.nxtbook.com/atp/MaintenanceTechnology/epjulyaug2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epjune2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epmay2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epapril2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epmarch2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epfeb2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epjan2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epnovdec2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epseptoct2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epmay2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epapril2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epmarch2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epfebruary2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epjanuary2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epdecember2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epnovember2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epoctober2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epseptember2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epaugust2018
https://www.nxtbook.com/atp/MaintenanceTechnology/0818schneider
https://www.nxtbook.com/atp/MaintenanceTechnology/epjuly2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epjune2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epmay2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epapril2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epmarch2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epfebruary2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epjanuary2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epdecember2017
https://www.nxtbook.com/atp/MaintenanceTechnology/epnovember2017
https://www.nxtbook.com/atp/MaintenanceTechnology/epoctober2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtsept2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtaugust2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjuly2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjune2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtmay2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtapril2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtmarch2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtfebruary2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjanuary2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtdecember2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtnovember2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtoctober2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtseptember2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtaugust2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjuly2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjune2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtmay2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtapril2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtmarch2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtfebruary2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjanuary2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtdecember2015
https://www.nxtbook.com/atp/MaintenanceTechnology/mtnovember2015
https://www.nxtbook.com/atp/MaintenanceTechnology/mtoctober2015
https://www.nxtbook.com/atp/MaintenanceTechnology/mtseptember2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTAugust2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTJuly2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTJune2015
https://www.nxtbook.com/atp/MaintenanceTechnology/M
https://www.nxtbook.com/atp/MaintenanceTechnology/0415endress
https://www.nxtbook.com/atp/MaintenanceTechnology/MTApril2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTMarch2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTFebruary2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTJanuary2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTDecember2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTNovember2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTOctober2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTSeptember2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTAugust2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTJuly2014
https://www.nxtbookmedia.com