Why is your current PM Program not Effective?

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

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©©

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©©

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©©

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©©

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

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©©

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©©

Why is your current PM Program not Effective?

Ricky Smith CMRP, CRL CPMM, CMRT

Why is your current PM Program not Effective?