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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
Poll – Are current PMs Effective?
Copyright 2010Copyright 2010 GPGPAlliedAllied©©
Copyright 2010Copyright 2010 GPGPAlliedAllied©©
Definition of Insanity
Doing the same thing over and over again and
expecting a different resultexpecting a different result
Copyright 2010Copyright 2010 GPGPAlliedAllied©©
Killer PMs
Ever heard of them?
Copyright 2010Copyright 2010 GPGPAlliedAllied©©
Without Proper PM Proactive Work is not achievable
Copyright 2010Copyright 2010 GPGPAlliedAllied©©
• 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©©
With these issues what do we have?
“High Variation in our Maintenance Process”
Copyright 2010Copyright 2010 GPGPAlliedAllied©©
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©©
Reduce Variation
Copyright 2010Copyright 2010 GPGPAlliedAllied©©
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©©
“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©©
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©©
Copyright 2010Copyright 2010 GPGPAlliedAllied©©
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©©
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©©
PF Curve
Copyright 2010Copyright 2010 GPGPAlliedAllied©©
I to P – PF Curve is not seen
Copyright 2010Copyright 2010 GPGPAlliedAllied©©
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
How to optimize your PM Program?
Copyright 2010Copyright 2010 GPGPAlliedAllied©©
Step 1: Educate Your Staff
Copyright 2010Copyright 2010 GPGPAlliedAllied©©
Educate Your Staff, Cont.
Copyright 2010Copyright 2010 GPGPAlliedAllied©©
Educate Yourself
Copyright 2010Copyright 2010 GPGPAlliedAllied©©
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©©
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©©
Step 4: Re-write your PMs focused on Failure Modes
Copyright 2010Copyright 2010 GPGPAlliedAllied©©
NOTE: Re-Write Your PMs so they are Repeatable
Copyright 2010Copyright 2010 GPGPAlliedAllied©©
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©©
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©©
“Excellence is a Habit”
- Aristotle, 330 BC
Copyright 2010Copyright 2010 GPGPAlliedAllied©©
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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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
  • 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©©