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A Day in the Life of a Proactive PdM Technician                       By Ricky Smith and Carey RepaszWhat value does a PdM...
this one issue that causes more pain to an organization than any other       and management wanted to know “how much longe...
A Potential Failure (Low Defect Severity- time to plan and scheduleproactive work) is an identifiable physical condition w...
Key Learning Point: If your maintenance process is reactive then your PdMTechnicians will be reacting to the urgent and em...
   …an electrical technician refuses to use a torque wrench on a loose       electrical connection found through infrared...
Early Morning for the Planner:Field inspections – Armed with an the results from PdM, PM, and Work Request,Job Inspection ...
the job is scheduled for execution. The planner will also need to review thestatus of parts previously ordered and update ...
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A Day In the Life Of a Proactive Maintenance PdM Tech

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A Proactive Maintenance Technician is a highly-trained professional expert in his skills area who has knowledge of other skills areas, including safety and production, and a desire to learn more. He knows and can implement a Failure Modes Driven Maintenance Strategy for any piece of equipment.

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A Day In the Life Of a Proactive Maintenance PdM Tech

  1. 1. A Day in the Life of a Proactive PdM Technician By Ricky Smith and Carey RepaszWhat value does a PdM Technician provide to a Proactive Organization?  The ability to identify a defect or unacceptable condition that will lead to equipment failure and unexpected downtime. The purpose of early defect identification is that work can be planned, scheduled, and executed without getting close to a failure on critical assets.  We are using the PF Curve to demonstrate this message. PdM Technologies VS PM (How much risk are you willing to take?) Copyright 2011, GPAlliedThe ability for maintenance work to be scheduled in the windows of opportunityoperations/productions offers us the chance to run as much production aspossible without an upset. We want production to produce as much qualityproduct as possible with minimal interference from maintenance.What value a PdM Technician cannot provide a Proactive Organization?  “Estimate of when the failure will occur”. The focus is on detection of defects that are random in nature. To attempt to trend the propagation of a defect and forecast the actual time of functional failure is a difficult proposition as well as a very poor use of the technician’s time. The defect will never be cheaper to address and our work execution processes must be utilized to address the timing of repairs, not the PdM team. I have seen
  2. 2. this one issue that causes more pain to an organization than any other and management wanted to know “how much longer will it run”. My answer always is “how much risk are you willing to accept”. After a while people lose confidence in PdM Technologies.  “Predictive Maintenance is not a true term”. On Condition Monitoring is the true definition of PdM because we are measuring the condition of specific failure modes are a specified time and it may be 30-90 days because a reading is taken again.  “If you really want to know what is the most effective method for addressing failure modes we may want to begin by determining what the most dominant failure pattern in your organization”. Less than 2% of organization can identify this failure pattern statistically because they do not have the data from their maintenance software to support such a decision. If you look below it shows that during the Nowlan and Heape study of the 1960s they found most failures were random. Failure Patterns from Nowlan and Heap Study, 1960sYou could identify your dominant failure patterns for your equipment if yourfailure data were available and accurate. I am sorry we are all out of crystal balls.Where does proactive work come from?Here is how this PM and PdM Work breaks out;PM Execution: 15% of WorkResults from PM: 15% of WorkCondition Monitoring Execution: 15% of WorkResults from Condition Monitoring: 35% of Work (planned and scheduled work,Emergencies not included “PdM’s focus is on the future not today’s problems”
  3. 3. A Potential Failure (Low Defect Severity- time to plan and scheduleproactive work) is an identifiable physical condition which indicates a functional failure is imminent and is usually identified by a Maintenance Technician usingPredictive Maintenance or Quantitative Preventive Maintenance. Copyright 2011, GPAlliedAt the beginnings of the maintenance day shift:The day begins with the PdM tech reviewing any equipment which has beenrepaired or replaced in the past 24 hours. If any equipment has been changed orrepaired the PdM Tech who handles can identify specific failure modes for thework completed will conduct follow up inspections of repairs for the purpose ofQA/QC that the defect has indeed been removed and that no new defects havebeen introduced as a result of maintenance activity. If a defect is identified, a newwork request is written by the PdM Technician to make the repair. On the workrequest will be the cause of the potential failure. This happens many timesbecause of “human induced failures” either with your current maintenancetechnicians not having effective procedures with specifications or your rebuildvendor now having any or following them. This inspection is critical to continuousimprovement of maintenance processes and establishing buy in of PdM.The correct method for repair or replacement of anything on a critical orimportant asset would be for a PdM Technician to conduct a baseline and tellmanagement if the equipment is defect free or not after the work. This goes fornext installations as well.Planned and Scheduled Work: The PdM Technician has a planned andscheduled route to conduct his/her inspections and to conduct baseline readingson repaired or replaced equipment during the day. This is a busy job if donecorrectly. Here is how their schedule may look for one day.
  4. 4. Key Learning Point: If your maintenance process is reactive then your PdMTechnicians will be reacting to the urgent and emergency work so their true valueis diminished.“You know you are in Reactive Maintenance using PdM when…”  …management asks a PdM technician the question “how long a piece of equipment last before it fails”? So a PdM Technician may get it right 40% (I doubt it) of the time, what if we could get it right 98% of the time? Sorry all PdM Crystal Balls are sold out.  …a company only uses Vibration Analysis and Infrared Technologies. So a technician can only identify potential failures on specific failure modes addressed by the two technologies. What about the failure modes which can only be address by ultrasound, UT, MCA, etc?  …company makes a repair after a defect (ex: loose electrical connection) however no Infrared Technician insures the defect has been identified after the electrical defect has been identified. Such as these loose electrical connections below. Outage Complete but has the Defect Been Eliminated? Copyright 2011, GPAllied  …Ultrasound is the only used for compressed air leaks.  …PdM Technicians do not even know each other and never work together.  … a company’s PdM program is not focused on specific failure modes so they conduct “too much PM”.  … no one uses infrared technology for low voltage applications, only high voltage. See pictures below. Copyright 2011, GPAllied
  5. 5.  …an electrical technician refuses to use a torque wrench on a loose electrical connection found through infrared inspection. How long will it take for the connection to burn up or become loose again? See example below. Allen Bradley Breaker Torque Manual  …if your maintenance technicians do not use repeatable effective work procedures. Expect a lot of findings by the PdM Group.  …if your main source of Failure Mode identification is when something fails you may be in reactive maintenance. Proactive PdM Daily Schedule Example Work Order Scheduled Conduct Take Readings Write WorkNumber/Schedule Work Baseline Request 0630 XXX-111 Pre-shift Overnight Repairs No Defect Detected Not Required Validation0700: XYZ-123a PdM Route No Defect Detected Not Required0730: XYZ-123b PdM Route Defect Detected Yes08:30: XTZ-123c PdM Route No Defect Detected Not Required0900: Emergency AC Induction Defect Detected – Use Maint WO Motor Replaced Vendor called Techs WO Number for Emergency13:00 XYZ-123d PdM Route Defect Detected Yes14:00 Urgent WO New Gearbox No Defect Detected Yes for Oil Installed by Baseline taken Analysis construction Oil Analysis sent out 15:00 – Work End of Shift CloseoutAvailable for EMCallout if required
  6. 6. Early Morning for the Planner:Field inspections – Armed with an the results from PdM, PM, and Work Request,Job Inspection forms, and a digital camera, the planner will begin making his/herinspection of all of the job sites. The planner has established a logical route tominimize travel time and will make notes of the specific needs of the request, anyancillary work that should be completed by the mechanic while at the job site,and all of the other applicable information required for a well planned job. Theplanner will make note of the complexity and predictability of the various issuesrelative to the particular job in order to create a job plan most effective yet suitedto the particular job. Also, the planner will pay particular attention to job issueswhere significant delays were identified in the Wrench Time study.Understanding and watching for complexity, predictability, and likely wrench timelosses will enhance the likelihood of creating a job plan that will minimize delaysduring execution and result in a high performing work force. More on thesetopics can be found in the 3rd edition of “Planning and Scheduling Made Simple”,Smith and Wilson.Immediately after completing field inspections is a good time to start orderingparts, or at least creating a list of parts to order, depending on the time availablebefore meeting with the supervisor, scheduler, and maintenance coordinator. Planning and Scheduling Using PdM Copyright 2011, GPAllied In particular, identifying the parts that will require more than 24 hours to obtainwill be important. These parts should be ordered today and the status should bechanged to “Waiting At this point in the process, it is not known when the job willactually be scheduled so, any parts not on site should be ordered on the sameday they are identified as a need. Parts that are available from the storeroomshould be put on reserve so that they will be available for ordering the day before
  7. 7. the job is scheduled for execution. The planner will also need to review thestatus of parts previously ordered and update the status to “Ready to Schedule”on the work request where all parts have arrived and storeroom parts are all onreserve. Some organizations go ahead and have storeroom parts delivered andplaced in Parts Kit boxes for each job. This process can work fine however, onedraw back is when jobs get pushed to the future for execution, you can end upwith a lot of Parts Kits to keep track of or, you can end up sending some stuffback to the store room if jobs get canceled for what ever reason. If you have afirm parts reservation system, it will be the best of both worlds where the partscan’t be bought out for a different job, yet if the job gets cancelled it doesn’t haveto be returned. Less handling and better inventory accuracy provided by thereservation approach will reduce costFrom a PdM Technician’s standpoint his/her time needs to be scheduled tovalidate a defect which has been eliminated and establish a baseline anytime arepair is made. If you do not conduct this expect unexpected failures will occurand makes people believe PdM is not effective.It may be a great idea to use your PdM Technician to assist with the identificationof causes of equipment failures as well. They can assist in Root Cause Analysis,repeatable equipment or process issues, etc.If you have questions or would like a one hour private WebEx for yourcompany on the subject send an email to Ricky Smith, rsmith@gpallied.com orCarey Repasz, crepasz@gpallied.com.A failure Mode Driven Strategy is what every company needs.

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