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| Maintenance Best Repair Practices plus CMRT |
The SMRP (Society for Maintenance and Reliability Professionals) offers the CMRT (Certified Maintenance and Reliability Technician), which I took the exam and passed. Think about how more effective your maintenance technicians would be to optimize reliability if they were skilled and trained.
In 1980 I was hired a the plant where I began my career as a proactive maintenance technician. Everyone who desired to work at a "World Class Maintenance" department (ALUMAX MT HOLLY) had to take a series of test (really they were hiring maintenance mechanics, electricians, and electronic technicians). The first set were written tests and given at night. If you passed these test you went on to take the "hands on" test, coupling alignment, bearing installation, hydraulics, etc. What I learned was what it meant to be a true Proactive Maintenance Technician.
Over my career as a Proactive Maintenance Technician, Proactive Maintenance Supervisor, Proactive Maintenance Manager and Proactive Maintenance Engineer was it is much easier and fun to work in a proactive maintenance organization. I took the CMRT and passed so your technicians could pass it as well and if not they can take it again but I highly recommend they receive training in "Maintenance Best Repair Practices".
I want to challenge all Maintenance Managers to look for an organization, technical college, skills training company, etc. and challenge your maintenance technicians to take a step forward and take the CMRT (Certified Maintenance and Reliability Technician) Exam from SMRP. If they do not pass that is OK, send them to additional training and have them take the exam again. Remember a great employee may not be the best maintenance technician. When I was a Maintenance Supervisor it was always exciting to have maintenance techs who were willing and able to learn (and 99.9% are willing able). Success in training leads to success in job satisfaction and optimized reliability.
The following information is a sample of the requirements to become a CMRT. To learn more about the CMRT go to: https://www.smrp.org/Certification/CMRT-Certification and contact me if you have questions.
Proactive Maintenance
-Maintenance and Production Responsibilities
-Defect Elimination from Human Induced Failures
-Maintenance Planning
-Maintenance Scheduling
-Work Execution
-Work Order Close Out
-Failure Reporting Analysis and Corrective Action System (FRACAS)
-MTBF/MTTR/MTBR Expectations
Reactive Maintenance
-Maintenance and Production Responsibilities
-Defect Elimination from Human Induced Failures
-Maintenance Planning
-Maintenance Scheduling
-Work Execution
-Work Order Close Out
-MTBF? MTTR? MTBR?
Safety
-Blood borne pathogens
-Confined space entry
-Electrical safety
-Emergency response (ER) and evacuation
-Environmental compliance
-Ergonomics
-Eye protection
-Fall protection
-Fire safety
-HAZCOM/MSDS
-Hearing conservation
-Ladder safety
-Lockout/tagout procedures
-Personal protective equipment (PPE)
-Process safety management (PSM)
-Respiratory protection
-Rigging
-Safety system and devices
-Scaffolding
Production/Maintenance Interaction
-Proactive Maintenance Process Overview
-Reactive Maintenance Process Overview
-Proactive Production Process Overview
-Reactive Production Process Overview
-Defining Roles and Responsibilities (RACI)
-Maintenance / Production Responsibilities
Exercise: Define Roles and Responsibilities using RACI during:
- Preventive Maintenance
- Predictive Maintenance
- Breakdowns
Pre-use inspection on maintenance tools and equipment
Safely before, during, after use of:
- Cranes and hoists
- Field machinery and tools
- Ladder safety
- Rolling stock/mobile equipment (e.g., mobile cranes, man-lift/scissor lift, fork lift)
- Shop Machinery and Tools
- Rigging Equipment, shackles, chains, slings, tools
- Use of equipment in accordance with manufacturers, specifications, and safety policies
Knowledge of the following:
- Equipment and tool specifications
- Established equipment and tool-safety policies and procedures
-Use measurement tools/equipment for maintenance tasks
-Measurement tools (e.g., rulers, gauges, tapes, micrometer, calipers, lasers)
-Proper Application of tools (e.g., rulers, gauges, tapes, micrometer, calipers, lasers)
-Basic math (e.g., fractions, addition, subtraction, multiplication, division)
-Calibration requirements for measurement tools (e.g., torque wrench, calipers, alignment tools) -Conversion of appropriate measurement and engineering units
-Measurement principles (e.g., mass, force, motion, distance, acceleration, power, fluid, bulk)
Handle all maintenance materials and parts in accordance with established standards
-Procedures in order to prevent damage to the parts and equipment. 1. Company safety policies
-Material handling techniques and procedures
-Material storage procedures
-Original equipment manufacturers' (OEM) instructions
Adhering to established site standards
-Removing all maintenance-related parts and waste in order to ensure a safe and orderly job site
-Facility and regulatory policies on housekeeping
-Hazards of improper housekeeping
-Proper organization and cleaning of job site
Document maintenance activities using the facility’s maintenance management system
-Closing a Work Order
-Record history
-Assist with planning and scheduling
-Support root-cause failure analysis
-Planned and scheduled work
Preventive and Predictive Maintenance
- Function/Functions of equipment
- Operating parameters and baseline conditions
- How to use preventive and/or predictive maintenance according to the work plan to maximize mean time between failures.
Company safety, health, and environmental policies
- Equipment function and use
- Predictive maintenance procedures
- Preventive maintenance procedures
Predictive Maintenance techniques (Maximize MTBF)
- Oil analysis
- Thermography (mechanical and Electrical)
- Ultrasound
- Vibration Analysis
- Observing equipment performance and collecting performance data to maximize mean time between failures (MTBF).
- Requirements of Predictive Maintenance
Lubrication
- Equipment specification
- Filtering systems
- Lubricant specifications
- Lubricating systems
- Lubrication principles
- Lubrication route
- Lubrication Processes (Hydraulic system, bearings, etc.)
- Lubrication schedule adherence
- Lubricate equipment to specifications to ensure reliable performance and prevent damage
- Company safety, health, and environmental policies
Alignment inspection/execution on rotating equipment to ensure reliable performance
(e.g., pumps, fans, blowers, turbines, gearboxes, compressors)
- Equipment functions and Operation principles for rotating equipment
- Performing alignment inspections and execution accordance with equipment specifications
- The candidate must demonstrate knowledge in the following:
- Company safety, health, and environmental policies
- Equipment alignment techniques (e.g., laser, reverse, straight edge, rim and face)
- Thermal growth Checks on safety systems and devices in accordance with equipment design
-Specifications in order to ensure reliable operation and protect employees
- Consequences of bypassing safety systems - Equipment design specifications
- Equipment functions (e.g., limit switches, photoelectric eyes)
- Operation of safety systems Troubleshooting and Analysis
- Gather information relating to a maintenance request
- Reviewing the work order
- Interviewing operations personnel in order to determine the general nature of the problem.
- Maintenance Techs must demonstrate knowledge in the following:
- Effective interpersonal relations
- Equipment and/or processes
Maintenance work order systems
- Verify that the problem is valid by systematically testing and/or observing the equipment’s performance, as conditions permit, in order to determine if a problem actually exists.
- Technicians must demonstrate knowledge in the following:
-Function and use of the equipment
-Process indicators (e.g., gauges, annunciators, Human Machine Interface [HMI] displays)
-Obtain appropriate technical documentation using facility resources in order to gain full understanding of designed operating parameters and/or sequences
-Facility resources (e.g., CMMS, technical library, engineering files)
-Operating parameters and sequences
-Technical documentation (e.g., schematics, P&ID, blueprints, O&M manuals, SOP, MSDS)
-Investigate previous maintenance activities, as conditions require, by reviewing equipment history in order to identify information that will facilitate troubleshooting.
Facility maintenance record systems
- Facility preventative maintenance scheduling programs or systems
- Preventative maintenance techniques and theories (e.g., lubrication, seals and bearings, alignments)
-Identification of cause of a problem using a systematic process of elimination in order to determine what is causing the malfunction - Equipment and/or process design parameters - Hazards involved with operating and/or maintaining specific process equipmen - Systematic troubleshooting and analysis
Corrective Maintenance
Task 1: Verify troubleshooting analysis by disassembling and inspecting components
- Application of established procedures in accordance with applicable standards and guidelines in order to confirm that the identified corrective action is appropriate.
The candidate must demonstrate knowledge in the following:
- Common mechanical systems (e.g., lubrication, seals and bearings, alignment, power transmission, cams, cranks, pneumatics, hydraulics, thermodynamics, heat transfer, piping systems, steam systems)
-Correct use of tools and equipment, including measuring devices
- Equipment specifications
- Equipment and component functions
- Operation of equipment and components
- Results of troubleshooting analysis
Task 2: Repair the malfunction by performing required corrective maintenance tasks in accordance with best maintenance practices in order to return the equipment to the desired operating condition.The candidate must demonstrate knowledge in the following:
1. Common mechanical systems (e.g., lubrication, seals and bearings, alignment, power transmission, cams, cranks, pneumatics, hydraulics, thermodynamics, heat transfer, piping systems, fabrication, steam systems)
2. Correct use of tools and equipment, including measuring devices
3. Equipment specifications
4. Equipment and component functions (e.g., pumps, fans, blowers, turbines, gear boxes, compressors, fasteners, motors, piping systems, gaskets/packing, drive systems, conveying systems)
5. Equipment and component operation
6. Specific equipment repair procedures, applicable standards, and guidelines
Task 3: Monitor the equipment after it has been repaired while operating it under normal conditions in order to determine whether or not the repair was successful.
The candidate must demonstrate knowledge in the following:
1. Equipment and component functions (e.g., pumps, fans, blowers, turbines, gear boxes, compressors, fasteners, motors, piping systems, gaskets/packing, drive systems, conveying systems)
2. Equipment and component operation
Task 4: Release repaired equipment for return to service using standard operating procedures in order to resume normal and safe operations.The candidate must demonstrate knowledge in the following:
1. Company safety, health, and environmental policies
2. Equipment alignment techniques (e.g., laser, reverse, straight edge, rim and face)
3. Equipment functions
4. Thermal growth
5. Operation principles for rotating equipment
Task 5: Use maintenance tools and equipment in accordance with manufacturers’ specifications and established safety policies in order to ensure safety and efficiency.The candidate must demonstrate knowledge in the following:
1. Utilize equipment and tool specifications
2. Established equipment and tool-safety policies and procedures
Task 6: Use measuring tools and equipment in a manner that will ensure accurate measurements in order to perform maintenance tasks properly. The candidate must demonstrate knowledge in the following:
1. Application of specific tools
2. Basic math (e.g., fractions, addition, subtraction, multiplication, division)
3. Calibration requirements for measurement tools (e.g., torque wrench, calipers, alignment tools)
4. Conversion of appropriate measurement and engineering units
5. Measurement principles (e.g., mass, force, motion, distance, acceleration, power, fluid, bulk)
6. Measurement tools (e.g., rulers, gauges, tapes, micrometer, calipers, lasers)
Task 7: Handle all maintenance materials and parts in accordance with established standards and procedures in order to prevent damage to the parts and equipment.The candidate must demonstrate knowledge in the following:
1. Company safety policies
2. Material handling techniques and procedures
3. Material storage procedures
4. Original equipment manufacturers' (OEM) instructions
Task 8: Maintain housekeeping by adhering to established site standards and by removing all maintenance-related parts and waste in order to ensure a safe and orderly job site.The candidate must demonstrate knowledge in the following:
1. Facility and regulatory policies on housekeeping
2. Hazards of improper housekeeping
3. Proper organization and cleaning of job site
Task 9: Document maintenance activities using the facility’s maintenance management system in order to record history, assist with planning and scheduling, and support root-cause failure analysis.The candidate must demonstrate knowledge in the following:
1. Documentation systems (e.g., paper filing systems, computer filing systems, email)
2. Maintenance planning and scheduling
For the "Rest of the Story" and more information on the CMRT go to: https://www.smrp.org/Certification/CMRT-Certification If you have a question contact me via LinkedIn messaging, Ricky Smith CMRP
The Author: Ricky Smith CMRP, CMRT, CRL
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