4 Foundational Elements for Proactive Maintenance

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This presentation was designed to give maintenance and reliability professional fresh ideas for a long time problem, "Reactive Maintenance". Simple ideas lead to results.

The 4 Foundational Elements are:
#1 – Striking the Balance between PM and PdM
#2 – Work Prioritization
#3 – Managing the Maintenance Function
#4 – Eliminating Failures

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4 Foundational Elements for Proactive Maintenance

  1. 1. 4 Foundational Elements for Proactive MaintenancePresented by: Ricky Smith, CMRP Copyright 2012 GPAllied©
  2. 2. Foundation“The basis upon which something stands or is supported” - Merriam-Webster Dictionary Copyright 2012 GPAllied©
  3. 3. 4 Foundational Elements for Proactive Maintenance #1 - Striking the #2 – Work Priority #3 – Managing the #4 – Eliminating Balance Between Distribution Maintenance Failures PM and PdM Function “The Foundation by which Proactive Maintenance Stands” Copyright 2012 GPAllied©
  4. 4. Obstacles What obstacles may you face on this journey? Copyright 2012 GPAllied©
  5. 5. PF Curve – Understand in Detail Copyright 2012 GPAllied©
  6. 6. #1 – Striking the Balance between PM and PdM PM / PdM Copyright 2012 GPAllied©
  7. 7. PF Curve and Proactive Maintenance Copyright 2012 GPAllied©
  8. 8. #2 - Work Priority Distribution• Priority 1 and 2 Work is Reactive• Priority 3, 4, and 5 Work is Proactive Copyright 2012 GPAllied©
  9. 9. Work Priority Distribution – a few simple rules EMERGENT work is anything that is done as a Priority 1 or 2 CORRECTIVE work is anything done as a result of an inspection CORRECTIVE work should never be done as a P1 or P2 ROUTINE work is anything done as a PRIORITY 3 CORRECTIVE work can be done as Priority 3 CORRECTIVE work should be done as a Priority 4 and 5 Most CORRECTIVE work should be done as P4 or P5 if you embrace P-F mentality Copyright 2012 GPAllied©
  10. 10. #3 – Managing the Maintenance Function • Managing in a Proactive vs. Reactive State is Different • Reactive – Most work is accomplished in Priority 1 and 2 • Proactive – Most work is accomplished in Priority 3-5 Copyright 2012 GPAllied©
  11. 11. Managing the Maintenance Function Proactively “Work Prioritization is just a Tool” Step 1 – Identify your current state to Proactive State Step 2 – Identify the barriers keeping you from Proactive Step 3 – Develop a Plan with your staff, key technicians Step 4 – Execute, manage, adjust the plan and be patient Copyright 2012 GPAllied©
  12. 12. #4 – Failure Elimination Copyright 2012 GPAllied©
  13. 13. How to Eliminate Failures? • Eliminate the Reactive Environment • Typical Attributes of a Reactive Environment – Maintenance workforce not engaged – (maintenance zombies) – Proactive work environment not known – never seen one – Conducting PM on equipment that continues to fail • Create a Proactive Environment – Focus on Changing Organizational Behaviors (people will follow) – Visit a Proactive Maintenance Organization (Vision) – Provide Education and Training (Proactive Work Flow) • Repeatable / Effective PM, CM, Op Procedures • PM / PdM and the PF Curve • Planning • Scheduling • Work Execution (Procedure Based) • Failure Elimination – KPIs – MTBF by similar equipment types first (know where to focus) – Establish Failure Elimination Teams , Techs & Operators Copyright 2012 GPAllied©
  14. 14. Recap – Foundational Elements of Proactive Maintenance #1 – Striking the Balance between PM and PdM #2 – Work Prioritization #3 – Managing the Maintenance Function #4 – Eliminating Failures - “if this were easy everyone would be doing it” - “Keep things simple” - “Education, Vision, Alignment” Copyright 2012 GPAllied©
  15. 15. Questions / Comments To learn more on this topic – “Reliability Engineering Fundamentals” March 5-7, Charleston, SC – Andy Page Email me at: rsmith@gpallied.com – Copies of the slides – Need ideas – Questions Slides Location - http://tinyurl.com/Pro-Maint www.maintenancephoenix.com www.gpallied.com Copyright 2012 GPAllied©

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