Maintenance Technology September 2016 - 91
30
In cases such as these, it works well to assign shift
maintenance of small, multi-craft crews to specific
banks of equipment. They are the first responders
to these breakdowns. Coming off of break-in logs
kept by the operators, they insulate the balance
of the maintenance resources (the day crew) from
break-in work (Priority 1's and 2's). This allows
the other maintenance crews to complete their
Priority 3 schedules without interruption.
The challenge is managing fluctuations in
workload. This is addressed by the supervisor. It is
important to review the break-in logs daily. Open
entries older than eight hours are assigned to the
day crew by generating a work order. Conversely,
where workloads are low, the shift crew should
have ready bench work available when there are
no breakdowns.
Implement and Sustain It
A perfect plant-wide prioritization system will not
work unless it is used by the entire organization-
operations, engineering, maintenance, etc.
Implementation is critical to the success of
this system. If you have used a credible, crossfunctional team to design it, you have a head
start. These team members should be an integral
part of your implementation rollout, training,
and coaching.
While the Information Technology (IT) team may
be involved in setting up the system programming
and menus, they should not be the trainers. They
lack the operational knowledge to answer the
what-if questions that inevitably come up during
training. Namely, the IT trainer can't answer an
operator's question about the applicability of a
specific backup pump. Your cross-functional team
has that knowledge and the credibility with the
users. They are, in effect, your salespeople for
the system. IT can and should help provide the
training documentation. But in the end, the crossfunctional team provides the classroom delivery
and training exercises. If you need additional
trainers, prepare other operations people to fill
that need.
In the best possible case, the training should
include real examples for generating and
prioritizing work requests. Have trainees bring
real examples of the work they need done to
generate and prioritize requests live in the training
class. Then, the training should be conducted in
computer-equipped training rooms.
The follow-up coaching will monitor compliance
to the system and its guidelines for several weeks
after implementation training. The coaching is
necessary because the classroom cannot cover
every possible scenario. And some people do
not necessarily learn well, or at all, in a classroom
setting. Hands-on experience can be a more
effective teacher. Personal follow-up and coaching
will help. If you do not follow up closely on the
classroom training, bad habits will start and then
spread through the organization.
Coaches should go out into the work areas with
request generators to watch them generate live
requests. We have found that this will remove
barriers to compliance that were not known
before, such as someone's work area lacking
access to a useable computer. There can be
numerous fixes like that coming out through
coaching in the work areas.
Coaches also monitor the accuracy of
prioritization. Where they find errors, they should
consult with the requestor for clarification.
Interestingly, we have found that some of the
biggest violators are the managers above line
management. Those are the non-compliance
incidents we, as consultants, are asked to handle
because we have no career politics on the line.
SOLUTIONS AUGUST 2016
10127-4056 SMRP Solutions SE.indd 30
8/22/16 9:43 AM
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
Maintenance Technology September 2016 - 51
Maintenance Technology September 2016 - 52
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
Maintenance Technology September 2016 - 62
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