Efficient Plant Sept./Oct. 2019 - 32

department | on the floor
 Education and Training
 Administrative & Office TPM
 Safety, Health, and Environment.
The pillar that most companies
struggle with is rolling out autonomous
maintenance. It's important to note that
trades/technicians are not required to pick
up hand tools to implement it. The operators' main role is to detect any abnormalities. They are the first line of defense with
early awareness and diagnosis of issues.
My studies have shown that at least 50%
of the benefit can still be attained in this
way (without the operator picking up hand
tools or lubricating machinery).
When it comes to setting up autonomous- maintenance teams, it should be
done with trades/technicians and
maintenance making the decisions
together. I recommend using a core team
that performs workshops, area by area, to

show each team how to:
 create an effective workplace checklist
 set up workplace organization
 set up visual aids and error proofing
 do daily checks
 solve equipment problems.
This requires an investment in training

Looking to refocus or revitalize
your maintenance program?
Looking to prepare for ISO 55001 certification?
Does your program currently:
P Lack confidence in its

P Lack the time to

P Lack strategic direction?
P Lack effective communication?

P Lack succession planning?
P Lack effective work planning

maintenance data?

complete all work?

and scheduling?

If you answered YES to any of the above,
call Ken Bannister at ENGTECH
ENGTECH Industries Inc-
successfully implementing usable asset management
programs for over 27 years-at (519) 469-9173
or email kbannister@engtechindustries.com
and let's talk maintenance!

Helping People manage People who Manage Assets!

| EFFICIENTPLANTMAG.COM

and consistent leadership support. 5S
(sort, set in order, shine, standardize, and
sustain/self-discipline) is typically instilled
first because it is foundational. If you
struggle with performing standardized
work and the culture of discipline (the basics of 5S), it's best to take whatever time is
needed to first instill this core methodology. Otherwise your larger process to follow
(lean manufacturing, TPM, reliability) will
be sub-optimal and more likely struggle.
My studies have shown that companies
doing TPM also are less reactive when
maintaining their equipment. Only 37%
of companies were doing some level of
TPM. Those companies were averaging
27% reactive maintenance versus 35% for
those not doing TPM. Also, my data shows
that about every 4.5% to 5.0% reduction in
reactive maintenance/total maintenance
equates to a 1% reduction in maintenance
cost/replacement asset value. For many
organizations this is equal to millions of
dollars.
Very few facilities have been able to fully implement autonomous maintenance,
where the operator monitors equipment
health, ensures workplace organization,
and assists in repairs to the extent allowed
in local agreements. Greater teamwork,
better organized and cleaner work areas,
equipment status at a glance, and reduced
emergency events all combine for a more
efficient outcome. If the operator can get
involved beyond just visual aids, additional savings are possible. This is where the
productivity benefits can be doubled. EP

Based in Knoxville, Klaus M. Blache
is director of the Reliability &
Maintainability Center at the Univ. of
Tennessee, and a research professor
in the College of Engineering. Contact
him at kblache@utk.edu.

SEPT/OCT 2019

http://www.engtechindustries.com http://www.EFFICIENTPLANTMAG.COM

Efficient Plant Sept./Oct. 2019

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