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Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
Why is your current PM Program not Effective?
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Why is your current PM Program not Effective?

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Lack of an effective PM program is destroying the credibility of our maintenance organizations. "The 1st step to solving a problem is knowing you have one". Focus must be on optimizing your current PM …

Lack of an effective PM program is destroying the credibility of our maintenance organizations. "The 1st step to solving a problem is knowing you have one". Focus must be on optimizing your current PM program (PdM Program next). View the slides and when you are ready contact me for your next step, rsmith@gpallied.com

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  • 1. Why Preventive MaintenanceWhy Preventive 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 – Are current PMs Effective? Copyright 2010Copyright 2010 GPGPAlliedAllied©©
  • 3. Copyright 2010Copyright 2010 GPGPAlliedAllied©©
  • 4. Definition of Insanity Doing the same thing over and over again and expecting a different resultexpecting a different result Copyright 2010Copyright 2010 GPGPAlliedAllied©©
  • 5. Killer PMs Ever heard of them? Copyright 2010Copyright 2010 GPGPAlliedAllied©©
  • 6. Without Proper PM Proactive 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 issues what do we have? “High Variation in our Maintenance Process” Copyright 2010Copyright 2010 GPGPAlliedAllied©©
  • 9. Have you ever wondered 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 2010Copyright 2010 GPGPAlliedAllied©©
  • 11. Variation in PM Compliance 10% Rule of PM 2 28 282 2 28 30 Day PM = Due in 3 daysy y Copyright 2010Copyright 2010 GPGPAlliedAllied©©
  • 12. “The significant problems we 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 Driven Strategy 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 2010 GPGPAlliedAllied©©
  • 15. What is a Failure? “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 a Failure? • “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 2010Copyright 2010 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 optimize your PM Program? Copyright 2010Copyright 2010 GPGPAlliedAllied©©
  • 21. Step 1: Educate Your Staff Copyright 2010Copyright 2010 GPGPAlliedAllied©©
  • 22. Educate Your Staff, Cont. Copyright 2010Copyright 2010 GPGPAlliedAllied©©
  • 23. Educate Yourself Copyright 2010Copyright 2010 GPGPAlliedAllied©©
  • 24. Step 2: QA/QC PM 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: Perform a 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-write your PMs focused on Failure Modes Copyright 2010Copyright 2010 GPGPAlliedAllied©©
  • 27. NOTE: Re-Write Your PMs so they are Repeatable Copyright 2010Copyright 2010 GPGPAlliedAllied©©
  • 28. Step 5: Begin measuring 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 about Failure 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 a Habit” - Aristotle, 330 BC Copyright 2010Copyright 2010 GPGPAlliedAllied©©
  • 31. Questions • Send your questions to rsmith@gpallied.com • Tool Box Training Session are free and you can access them anytimey Copyright 2010Copyright 2010 GPGPAlliedAllied©©

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