Efficient Plant May 2018 - 11
1
feature | maintenance processes
STEP 1, IDENTIFICATION: The maintenance-
STEP 2, AUTHORIZATION: Work authorization
2
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
3
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.
EFFICIENTPLANTMAG.COM |
11
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Table of Contents for the Digital Edition of Efficient Plant May 2018
Editorial
Implementations
Six Steps That Cut Costs
Educating Work-REady Students
Revisiting Benefits Of A CMMS
Lube Safety Comes In Threes
SAP: What Does This SAP Error Mean?
Are Your Electrical Workers Qualified?
Is Your Site Susceptible To Cyber Threats?
Pinpoint Funny Motor-Ground Currents
Properly Select Pressure-Relief Valves
On The Floor
Solution Focus
Products
Index
Showcase
Seeking Reliability
Efficient Plant May 2018 - Cover1
Efficient Plant May 2018 - Cover2
Efficient Plant May 2018 - 1
Efficient Plant May 2018 - 2
Efficient Plant May 2018 - 3
Efficient Plant May 2018 - 4
Efficient Plant May 2018 - 5
Efficient Plant May 2018 - Editorial
Efficient Plant May 2018 - 7
Efficient Plant May 2018 - Implementations
Efficient Plant May 2018 - 9
Efficient Plant May 2018 - Six Steps That Cut Costs
Efficient Plant May 2018 - 11
Efficient Plant May 2018 - 12
Efficient Plant May 2018 - 13
Efficient Plant May 2018 - 14
Efficient Plant May 2018 - 15
Efficient Plant May 2018 - Educating Work-REady Students
Efficient Plant May 2018 - 19
Efficient Plant May 2018 - 20
Efficient Plant May 2018 - 17
Efficient Plant May 2018 - 18
Efficient Plant May 2018 - 19
Efficient Plant May 2018 - 20
Efficient Plant May 2018 - 21
Efficient Plant May 2018 - Revisiting Benefits Of A CMMS
Efficient Plant May 2018 - 23
Efficient Plant May 2018 - 24
Efficient Plant May 2018 - 25
Efficient Plant May 2018 - Lube Safety Comes In Threes
Efficient Plant May 2018 - 27
Efficient Plant May 2018 - 28
Efficient Plant May 2018 - SAP: What Does This SAP Error Mean?
Efficient Plant May 2018 - Are Your Electrical Workers Qualified?
Efficient Plant May 2018 - Is Your Site Susceptible To Cyber Threats?
Efficient Plant May 2018 - Pinpoint Funny Motor-Ground Currents
Efficient Plant May 2018 - Properly Select Pressure-Relief Valves
Efficient Plant May 2018 - On The Floor
Efficient Plant May 2018 - 35
Efficient Plant May 2018 - Solution Focus
Efficient Plant May 2018 - 37
Efficient Plant May 2018 - 38
Efficient Plant May 2018 - 39
Efficient Plant May 2018 - Products
Efficient Plant May 2018 - 41
Efficient Plant May 2018 - 42
Efficient Plant May 2018 - 43
Efficient Plant May 2018 - 44
Efficient Plant May 2018 - 45
Efficient Plant May 2018 - Index
Efficient Plant May 2018 - Showcase
Efficient Plant May 2018 - Seeking Reliability
Efficient Plant May 2018 - Cover3
Efficient Plant May 2018 - Cover4
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