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How To Develop A World Class Maintenance Team

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Developing a Highly Effective Maintenance Team requires discipline, a proactive process, etc. Do you have one?

How To Develop A World Class Maintenance Team

  1. 1. How to Develop a Highly Effective Maintenance Team Presented by: Ricky Smith, CMRP July 28, 2010 Copyright 2010 GPAllied©
  2. 2. A highly effective maintenance team can only happen when everyone has the same vision. Copyright 2010 GPAllied©
  3. 3. Our MISSION To Maintain an Asset – Keep in existing condition – Keep, preserve, protect Copyright 2010 GPAllied©
  4. 4. Two types of failures. • “A functional failure is the inability of an item (or the equipment containing it) to meet a specified performance standard and is usually identified by an operator”. • “A potential failure is an identifiable physical condition which indicates a functional failure is imminent and is usually identified by a Maintenance Technician using predictive or quantitative preventive maintenance” Copyright 2010 GPAllied©
  5. 5. The Vision • To be the best at what we do. • Seeking improvement everyday. • Learning is our watchword. Copyright 2010 GPAllied©
  6. 6. Potential Failures – Where to Detect them? Copyright 2010 GPAllied©
  7. 7. Our Goal Copyright 2010 GPAllied©
  8. 8. Step 1: Awareness of a Problem • Being aware we have a problem • Identify 4 KPIs to Track and Monitor  Reliability of Critical Assets - MTBF  (Mean Time Between Failure)  PM/PdM Effectiveness - PM vs EM Labor Hours  Repairs – Rework  PM/PdM Failure Modes - % of PM/PdM Addressing Specific Failure Modes of Critical Assets  Breaks to Maintenance Schedule - # of Breaks to Maintenance Schedule by Maintenance and Production • Post and trend KPIs for all to see • Discuss a KPI with the Team when it is not acting in an acceptable manner – find the root cause and develop a solution • Never talk negative or blame any group or person for a KPI which is unacceptable Copyright 2010 GPAllied©
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  14. 14. Step 2: Education for all Levels Define the Vision - PM/PdM - Planning / Scheduling, etc Value of Change - Management; Lower cost / higher output - Maintenance Management / less problems, breakdowns - Maintenance Techs / less stress, more pride What is a Failure Mode? “How something fails” – Most work should come from prevention or prediction of specific failure modes How do you Measure is your PM Program is Effective? – “PM Labor Hours vs Emergency Labor Hours” – Mean Time Between Failures Execution of work repeatedly and precisely – Repeatable Operations, PM, CM, Lube Work Procedures – “Reduce Variation” Copyright 2010 GPAllied©
  15. 15. Step 3: Integrate all Training into Work Flow • All training must be in sequence • All training involves coaching and mentoring • Make sure the training effectiveness is measurable Copyright 2010 GPAllied©
  16. 16. Step 4: Optimize the Use of Technology - CMMS/EAM - Reliability Software - Ivara - Meridium - Predictive Maintenance (not as a predictive tool but as a Failure Mode Detection Tool) - Master Plan Tracking Copyright 2010 GPAllied©
  17. 17. Step 5: Develop Guiding Principles Maintenance • We will eliminate all failures which we deem unacceptable • We will ensure all paperwork is completed on time and accurately • We will perform work only once • We will work with our production partners as a time • We will stay with production until equipment is operating to standard Production/Operations • Operators will care for the basic needs of their equipment • Operators will notify maintenance of any abnormality identified • Operators will stay on station during all breakdowns • Operators will write work request and notifications for all work Copyright 2010 GPAllied©
  18. 18. Step 6: Everyday we will improve Remember: Excellence must have a standard and in absence of a standard we have chaos Copyright 2010 GPAllied©
  19. 19. • If you want copies of the slides send me a request • If you want copies of my Tool Box Training Sessions send me a request – new copies every other week • Questions rsmith@gpallied.com “Let’s Make a Difference” Copyright 2010 GPAllied©

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