 |
| Let’s be honest with ourselves; You are in Reactive Maintenance when |
you are “Performing Preventive Maintenance” on Equipment that continues to fail (failing to meet the intent of the end user). The problem I am guessing is that your “Equipment is not at a maintainable level”. How to know if this is a problem? Ask yourself “does the equipment operate to specifications on demand or 100% of the time as required by production (rate, speed, capacity, quality required?”). Face the facts, If the equipment is not in a maintainable condition then it is impossible to perform Preventive Maintenance and expect it to be effective. I call this insanity.
Albert Einstein defined "Insanity" as, Doing the same thing over and over again and expecting a different result. "is this you?"
Albert Einstein defined "Insanity" as, Doing the same thing over and over again and expecting a different result. "is this you?" So, what is the solution:
1. Restore your equipment to a “Maintainable” and “Reliable” condition
2. The plan to restore your equipment is as follows;
a. Select the most critical asset you have (or just select one with production leadership)
b. Identify all defects (abnormalities) using visual inspection and condition monitoring technologies.
c. Write “Work Orders” for all work required.
d. Plan and Schedule all work required to “Restore” this equipment to a maintainable level.
-Maintenance Planning requires the work to be defined with step by step instruction, parts required, estimated downtime required (this is performed by identifying how long each step takes in order to perform the step to specification), specifications (torque, bearing clearance settings, etc.), safety requirements for the technicians and equipment, etc
-Once the equipment is restored you must warn people by posting this sign, shown at the top of this article, on or close to the equipment as possible.
So, what is the solution
1. Restore the equipment to a “Maintainable” and “Reliable” condition
2. Your plan to restore the equipment could follow this path;
- Select the most critical asset you have (or just select one with production leadership)
- Identify all defects (abnormalities) using visual inspection and condition monitoring technologies.
- Write “Work Orders” for all work required.
- Plan and Schedule all work required to “Restore” this equipment to a maintainable level.
WARNING: Maintenance Planning requires the work to be defined with step by step instruction, parts required, estimated downtime required (this is performed by identifying how long each step takes in order to perform this step to specification), specifications (torque, bearing clearance settings, etc.), safety requirements for the technicians and equipment, etc.
Schedule the work required for restoration. Schedule this work with production, no short cuts, estimate the restoration time and add 20% to it (things happen). The day prior to this event go through a "dry run" with production and maintenance team to ensure all potential problems are discussed and worked out. (no plan is perfect but I would want this plan to be executed as expected, no surprises if possible)
When all work is complete, Maintenance stays with the equipment: it is time to verify that the equipment is meeting the intent of the end user (Production) and running to specification for at least 2 hours, sorry a little overtime is cheaper than lost capacity and no one leaves the equipment for break or lunch.
Once the equipment is restored you must warn people by posting a sign on or close to the equipment that states: "Warning, Maintainable Equipment in this Area, No Reactive Maintenance or Production allowed" If you feel apprehensive or uncertain I would recommend you attend one of the following conferences and learn from others who have traveled this journey and been successful. You are not alone, trust me.
IMC, "International Maintenance Conference" in Fort Myers, FL, (my favorite), December 11-15 Learn more at: https://reliabilityweb.com/events/featured/imc-2017 The "Reliability Conference" in Las Vegas, Nevada (awesome time), April 23-27, 2018 https://reliabilityweb.com/events/featured/the-reliability-conference
Good luck and wish you the best..
The Author: Ricky Smith CMRP, CMRT, CRL
About:
To all my friends, The Maintenance Community on Slack is an incredible free space where over 1,500 maintenance and reliability professionals like myself share real life experiences with each other.
To join us, sign up here: https://upkeep.typeform.com/to/icC8EKPT
Post a Comment