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Why is your current PM Program not Effective?
The document discusses the ineffectiveness of current preventive maintenance programs and highlights the need for improvement in planning, scheduling, and execution to reduce equipment failures. It identifies common issues that lead to high variation in maintenance processes and advocates for focusing on failure modes to optimize maintenance strategies. Key steps for enhancement include educating staff, evaluating PM tasks, rewriting procedures, and measuring effectiveness and efficiency.
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Why is your current PM Program not Effective?
- 1. Why Preventive MaintenanceWhyPreventive Maintenance is not working for Youis not working for You Presented by: Ricky Smith, CMRP January 2011 Copyright 2010Copyright 2010 GPGPAlliedAllied©© January, 2011
- 2. Poll – Arecurrent PMs Effective? Copyright 2010Copyright 2010 GPGPAlliedAllied©©
- 3. Copyright 2010Copyright 2010GPGPAlliedAllied©©
- 4. Definition of Insanity Doingthe same thing over and over again and expecting a different resultexpecting a different result Copyright 2010Copyright 2010 GPGPAlliedAllied©©
- 5. Killer PMs Ever heardof them? Copyright 2010Copyright 2010 GPGPAlliedAllied©©
- 6. Without Proper PMProactive Work is not achievable Copyright 2010Copyright 2010 GPGPAlliedAllied©©
- 7. • 70-80 %of equipment failures are Self-Induced • Putting hydraulic fluid into a reservoir without filtering it • Welding on equipment without grounding• Welding on equipment without grounding properly • Aligning couplings without using a laser I l l b i ti l t i t• Improperly lubricating electric motors • Not using a torque wrench • No Repeatable Procedures PMs CM / Repair LubricationLubrication Copyright 2010Copyright 2010 GPGPAlliedAllied©©
- 8. With these issueswhat do we have? “High Variation in our Maintenance Process” Copyright 2010Copyright 2010 GPGPAlliedAllied©©
- 9. Have you everwondered why reactive i t ?maintenance occurs? Maintenance – To Maintain, Keep in Existing Condition • Direct work is low (wrench time is less than 30%) • Lack of effective Planning – Planning is not defined • Lack of effective Scheduling – Delays are commonLack of effective Scheduling Delays are common Failure Modes Driven Modifying Failure ModesDriven Strategy Driven Strategy Copyright 2010Copyright 2010 GPGPAlliedAllied©©
- 10. Reduce Variation Copyright 2010Copyright2010 GPGPAlliedAllied©©
- 11. Variation in PMCompliance 10% Rule of PM 2 28 282 2 28 30 Day PM = Due in 3 daysy y Copyright 2010Copyright 2010 GPGPAlliedAllied©©
- 12. “The significant problemswe face cannot be solved with the same level of thinking we weresolved with the same level of thinking we were at when we created them.” - Albert Einstein Copyright 2010Copyright 2010 GPGPAlliedAllied©©
- 13. Failure Modes DrivenStrategy is defined as maintenance strategies (PM/PdM) focused onmaintenance strategies (PM/PdM) focused on “prevention or identification of specific Failure Modes”Failure Modes . Copyright 2010Copyright 2010 GPGPAlliedAllied©©
- 14. Copyright 2010Copyright 2010GPGPAlliedAllied©©
- 15. What is aFailure? “A functional failure is the inability of an item (or the equipment containing it) to meet a( g ) specified performance standard and is usually identified by an operator”. • F. Stanley, and Heap, Howard F., Reliability-Centered Maintenance, Department of Defense Report Number A066-579, December 29, 1978 Copyright 2010Copyright 2010 GPGPAlliedAllied©©
- 16. What is aFailure? • “A potential failure is an identifiable physical condition which indicates a functional failure i i i t d i ll id tifi d bis imminent and is usually identified by a Maintenance Technician using predictive or quantitative preventive maintenance”quantitative preventive maintenance - F. Stanley, and Heap, Howard F., Reliability-Centered Maintenance, Department of Defense Report Number A066-579, December 29, 1978 Copyright 2010Copyright 2010 GPGPAlliedAllied©©
- 17. PF Curve Copyright 2010Copyright2010 GPGPAlliedAllied©©
- 18. I to P– PF Curve is not seen Copyright 2010Copyright 2010 GPGPAlliedAllied©©
- 19. Failure Patterns Bathtub Pattern A= 4% Initial Break-in period Pattern D = 7% W O t Random Pattern E = 14% Time Time Wear Out Pattern B = 2% Time Time Fatigue Pattern C = 5% Infant Mortality Pattern F = 68% Age Related = 11% Random = 89% Copyright 2010Copyright 2010 GPGPAlliedAllied©© Source: John Moubray, Nowlan & Heap
- 20. How to optimizeyour PM Program? Copyright 2010Copyright 2010 GPGPAlliedAllied©©
- 21. Step 1: EducateYour Staff Copyright 2010Copyright 2010 GPGPAlliedAllied©©
- 22. Educate Your Staff,Cont. Copyright 2010Copyright 2010 GPGPAlliedAllied©©
- 23. Educate Yourself Copyright 2010Copyright2010 GPGPAlliedAllied©©
- 24. Step 2: QA/QCPM Execution • Visit the job site • Ask questions Does the PM look effecti e to them?– Does the PM look effective to them? – Any ideas how we may improve it? – What is your biggest issue with PMs? • Post PM Effectiveness (PM hrs. vs EM Labor hrs.) Copyright 2010Copyright 2010 GPGPAlliedAllied©©
- 25. Step 3: Performa PM Evaluation PM Task Action Recommendation # of Tasks % of Tasks Man-Hours Represented Non-Value Added % Non Value Added (Delete) 1,640 8.2% 6,661 Reassign to Operator Care 1,380 6.9% 5,605 Reassign to Lube Route 2,856 14.3% 11,600 Replace with PdM 6 437 32 2% 28 222Replace with PdM 6,437 32.2% 28,222 Re-Engineer 5,200 26.0% 26,221 N M difi tiNo Modifications Required 2,487 10.4% 8,987 Totals 20,000 100.0% 87,297 Copyright 2010Copyright 2010 GPGPAlliedAllied©©
- 26. Step 4: Re-writeyour PMs focused on Failure Modes Copyright 2010Copyright 2010 GPGPAlliedAllied©©
- 27. NOTE: Re-Write YourPMs so they are Repeatable Copyright 2010Copyright 2010 GPGPAlliedAllied©©
- 28. Step 5: Beginmeasuring PM Effectiveness and Efficiency - Effectiveness: Mean Time Between Failure - Efficiency: PM Compliance using the “10% Rule of PM” Copyright 2010Copyright 2010 GPGPAlliedAllied©©
- 29. Learn More aboutFailure Modes • Use ISO 14224 as a help document (http://www.iso.org/iso/catalogue_detail.htm?csnumber=36979 If you need help let me know• If you need help, let me know • Workshops (http://www.alliedreliability.com/gpalliedtraining/us_middle_east_asia.asp) M i t E ll f M i t– Maintenance Excellence for Maintenance Supervisors (talk to me if interested) – Balancing PM and PdM (Intro to CBM)Balancing PM and PdM (Intro to CBM) – RCM Blitz – Developing Effective Work Procedures – Change Management Copyright 2010Copyright 2010 GPGPAlliedAllied©©
- 30. “Excellence is aHabit” - Aristotle, 330 BC Copyright 2010Copyright 2010 GPGPAlliedAllied©©
- 31. Questions • Send yourquestions to [email protected] • Tool Box Training Session are free and you can access them anytimey Copyright 2010Copyright 2010 GPGPAlliedAllied©©