10% Rule of Preventive Maintenance --- Begin the Conversation and Education with Production/Operation Leadership

It is time to wake up your leadership by follow these simple steps:
  1. Print a copy of this article and give a copy to your leadership team and ask they read the article and have a one on one discussion with you about the article the next day.
  2. Talk with your leadership team the next day about production losses, equipment breakdowns, production and maintenance cost.
  3. Send me an email once you have accomplished this task and I will provide you with next steps. If you have questions before or after you begin please ask. 
If you are executing Preventive Maintenance (PM) on equipment that continues to break down or your maintenance cost continues to increase, I recommend you read this article on the 10% Rule of Preventive Maintenance. This short explanation of the 10% Rule of PM may be what you need to take that next step in the journey to optimizing reliability or just reducing equipment failures.
"The 10% Rule of Preventive Maintenance is simple and it works"Here is how the 10% Rule of Preventive Maintenance works. The 10% Rule of PM states that if a PM is executed within 10% of a time frequency then it is considered compliant and within the standard. An example would be a monthly PM must be completed within 1-1/2 days on either side of the due date in order to be in compliant (I recommend you use 30 days as an average for a monthly PM calculation). The rational for applying this rule is, it reduces the variation of PM Execution time frequency. In maintenance we must identify and reduce variations in the maintenance process and this is a great example where it could be applied.
In the example below a 30 day PM is executed in June near the end of the month (too many problems at the beginning of the June so PMs had to be pushed back) at the beginning of July the same PM is executed (things were going well at the beginning of the month so one must complete yourPMs because we know bad days are coming), in August the PM is executed on the 28th of the month (because of too many problems at the beginning of the month). This 30 day PM was actually a 28 day PM, a 3 day PM, and a 58 day PM. See the problem? 
This problem is worse when a company uses a CMMS (Computerized Maintenance Management System) or EAM (Enterprise Asset Management) that kicks out all PMs for the month on the 1st and you think we have 30 days to complete them. The crew or planner are told to make sure these PMs are completed sometime within the month so they can meet 100% PM Compliance. Can you see the problem now? In many organizations the focus is on PM Compliance rather than stopping equipment failures.
The 10% rule of Preventive Maintenance was first developed in the 1990s and I have been applying and teaching this methodology all over the world and have seen results which truly amazes maintenance and operations leaders.
Below are some basic principles which must be followed when applying the 10% Rule of PM:
Principle #1: Management must be totally committed and believe in this process.
Principle #2: Ensure your PM Procedures are repeatable with instructions, steps, specifications, etc.
Principle #3: It is acceptable to have low PM Compliance when you first begin this journey, however, what is not acceptable is for the PM Compliance not to improve.  
Principle #4: When measuring PM Compliance using the 10% Rule be sure and track total maintenance cost, mean time between failure of critical assets, emergency vs pm labor hours to insure management sees the results of this process. 

Principle #5: Begin application of this process to your organization's most critical assets or take one area or one equipment type at a time. Do not attempt to apply this to all your assets overnight.
Principle #6: As failures are reduced, expand this process throughout your organization. Be sure before you move to the next area, asset, etc. that repeat-ability of the 10% Rule PM has demonstrated success over 6-12 month period. 
Develop and apply your own principles as you gain knowledge and experience using this process.  Many companies will never apply the 10% Rule of PM because of many reasons and that is ok, what is not ok is to say it does not work. Alcoa Mt Holly outside of Charleston, SC, USA has been applying this rule to 100% of their assets for many years and have shown tremendous success as a result. 
In the chart below you will see their Maintenance Cost is 2.0% as a Replacement of Asset Value (international standard for evaluating maintenance cost - 2.0% is world class) and their PM compliance is 85.77%. This is a large aluminum smelter with a carbon plant and cast house in case you wanted to know how large this plant is. You can Google "Alcoa Mt Holly" if you wish to learn more about their plant or see a picture of the site.
The challenge today is for you to determine if this journey is worth taking. If you are not applying the 10% Rule of PM and have a high PM compliance but equipment continues to fail then the 10% Rule of PM is for you. Be sure you develop a well thought out plan before you execute. [email protected]

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