This is a general overview of the steps required to implement an effective maintenance program and eliminate unplanned losses

1. What are you doing
about your next
failure?
Methodology for Implementing a Reliable Maintenance Process
By Anthony Pesce CMRP
This presentation is to provide a general
overview showing how various tools can be used
together to build a successful maintenance
process. Individual tools mentioned may require
a more in-depth look

2. Not all equipment is
equal.
Not all equipment will
have the same impact
on the process.
Some equipment
requires special tools,
training and just takes
longer to repair.
(MTTR)
Some equipment just
requires more attention than
others. (MTBF)
Some equipment has to
meet regulatory
requirements
Not all equipment will
have the same risk of
failure.
How Can I possibly
prevent a failure in
all of this?!
A failure is when the asset or component no longer can safely perform the task it was
designed to do without consequence to safety, people, equipment or product.

3. Step 1 Classification
The classification step or Criticality
assessment brings the equipment at
the highest levels of risk in to view :
• What is the impact of a failure?
• How likely will it fail?
• How hard is it to fix?
Equipment is commonly
divided in three groups A,
B and C. With “A” being
the most critical.
Sometimes 0-9 is also
used.
Know your risks and concentrate your efforts proportionally on those risks
A B C

4. Concentrate of the assets which are at the highest risk- “A” Critical
• Understand the current condition of this equipment.
• Criticality
• Inspections
• Performance Data
• Maintenance Records
• Restore the equipment to a base line condition
• One time event or
• Scheduled activities over a set period of time
• Improve known weaknesses
• Build an information system
• Centerline data
• Inspection guidelines gather information from the
restore phase
• Alarm levels and maintenance triggers
• BOM Data (Bill of Material)
• FMEA (Failure Mode Effects Analysis) For each “A”
critical asset to organize failure modes.
Understand, Restore and Build provide the basic structure to maintain work completed- Build Sustainability
Identify your
risks and your
losses- Loss
Analysis
Once you know where the
losses are hit those- stop
some of the fire fighting
to free up your team to
continue.
What standards
do I need to
maintain?
You should
read a little
more on this

5. Assign- Use the
information acquired
in the Understand,
Restore and Build
steps to assign a
maintenance strategy
Time Based
Maintenance Task
(TBM)
Condition Based
Maintenance Task
(CBM)
• Keep equipment at base
line condition by
completing inspections
carried out at
determined intervals.
(Inspect/Repair/Replace)
• Maintain base line condition
by replacing or adjusting
components at predefined
intervals. (Adjust/Replace)
• Maintain baseline condition
at a constant level by
monitoring the equipment
using special tools scheduling
repairs at opportune times.
There’s a lot here…
You should review
planning, scheduling,
A computerized
maintenance system
(CMMS), training
See you can
predict the
future

6. • Classification
• Understand
• Restore
• Build
• Assign
Whew,
got that
done…
But is it
working?!
• Loss Analysis/ Loss
tree
• Working Principles
• Root Cause Analysis
• Who, What, When,
where, Why and
How?
• Why, Why, Why,
Why, Why?
• Fishbone
• One point
lessons
• PM Optimization
• Clean Inspect
Lube (CIL)
Autonomous
Maintenance
• Kaizen
• Training
Feedback- With any process there
must be key performance
indicators used to evaluate the
effectiveness. Where ever the
process does not meet
expectations there should be
corrective actions aimed at
process improvements which
feed back in to the system for
sustainability.
There might
be a few
more things
to study