As the industry has evolved, so have the practices and philosophies for how and when to perform maintenance and lubrication. More options and tools are now available to guide the actions of personnel for nearly all lubrication tasks.
The document discusses best maintenance repair practices and identifies issues that commonly prevent organizations from following them. It finds that 70% of equipment failures are self-induced due to maintenance personnel not knowing or following basic maintenance practices. Surveys showed over 90% of maintenance personnel lacked complete mechanical maintenance fundamentals. The document outlines best practices such as taking a proactive rather than reactive approach, ensuring maintenance personnel have requisite skills, and providing discipline and direction to follow practices. It recommends organizations identify whether issues exist, determine the causes, provide training to change maintenance culture, and develop a proactive maintenance strategy to implement changes and measure financial gains from following best practices.
Advanced Maintenance And Reliability (Best Maintenance and Reliability Practi...Ricky Smith CMRP, CMRT
Maintenance and reliability has taken great strides toward managing asset reliability by applying known best practices in maintenance and reliability finding that they can optimize reliability and reduce total cost and reduce risk by applying known best practices. However, if not most organizations are still trapped in the old way of thinking. Read this article and see where you stand.
Most companies don’t measure mean time between failures (MTBF), even though it’s the most basic measurement that quantifies reliability. MTBF is the average time an asset functions before it fails. So, why don’t they measure MTBF? Let’s define reliability first before we go any further.
Reliability: The ability of an item to perform a required function under stated conditions for a stated period of time
So why don’t we measure Mean Time Between Failure. This articles discusses this issue.
The concepts contained within Lean Manufacturing are not limited merely to production systems. These concepts translate directly into the world of maintenance and reliability.
At the core of Lean Manufacturing philosophy is the concept of elimination of waste. It is about getting precisely the right resources to precisely the right place and at the right time to make only the necessary products in the most efficient manner possible.
The concepts of the elimination of waste can be easily traced to Benjamin Franklin. Poor Richard encouraged the concepts of elimination of waste in numerous ways. Adages like “Waste not, want not”, “A penny
saved is two pence clear…Save and have” and “He that idly loses 5s. [shillings] worth of time, loses 5s., and might as prudently throw 5s. into the river.” Yes, it was Benjamin Franklin that educated us about the possibility that avoiding unnecessary costs could return more profit than simply increasing total sales.
It was Henry Ford who took the concept of the elimination of waste and integrated it into daily operations at his manufacturing facilities. Mr. Ford’s attitude can be seen in his books, “My Life and Work” (1922) and in “Today and Tomorrow” (1926) where he describes the folly of waste and introduces the world to Just-In-Time manufacturing. Mr. Ford cites inspiration from Benjamin Franklin as part of the foundation of these concepts.
However, it wasn’t until Toyota’s Chief Engineer, Taiichi Ohno systematized these concepts and the concept of pull (Kanban) into the Toyota Production System and created a cohesive production philosophy that was focused on the elimination of waste, that the world was able to see the real power of Lean Manufacturing. Interestingly enough, when Mr. Ohno was asked about the inspiration of his system, he merely laughed and said he read most of it in Henry Ford’s book.
Part 1 of this report will focus on one very specific Lean Manufacturing method known as 5S. This section will detail how a 5S initiative focusing on a plant’s Preventive Maintenance (PM) Program can immediately unlock resources within that maintenance department and make the PM process significantly more effective and efficient. Part 2 will look at the Deadly Wastes (Muda) of manufacturing and how elimination of these wastes is also a focus of the reliability process. Part 3 will discuss the overall objectives of Lean Manufacturing and parallel them with the overall objectives of the reliability process. Part 4 will discuss Poka- Yoke (mistake proofing) and see how several standard maintenance techniques are, in fact, Poka-Yoke techniques. A brief discussion of Kaizen and how both Lean Manufacturing and Maintenance and Reliability initiatives share these very same goals and objectives will summarize the entire report.
10 Things an Operations Supervisor can do Today to Improve ReliabilityRicky Smith CMRP, CMRT
Continuing the series that started with maintenance technicians and supervisors, if you are new to the position of Operations Supervisor, what are some of the things you can begin working on immediately to improve reliability within the area you work?
This document outlines the fundamentals of an effective maintenance program. It discusses key aspects such as viewing maintenance as part of the manufacturing process, having clear roles and responsibilities, keeping equipment clean, using a maintenance management system to track work, developing maintenance strategies based on equipment criticality and failure modes, fixing breakdowns quickly using problem analysis, and ensuring maintenance staff have high skills and perform quality work.
Glossary. Maintenance and Reliability Body of KnowledgeEliezer Jimenez
This document defines terms related to asset and equipment maintenance management. It defines terms like achieved availability, active work order, annual maintenance cost, corrective maintenance, and preventive maintenance. It provides formulas for metrics like achieved availability and discusses maintenance organization structures like centralized and decentralized models. The document is intended to define terms used for benchmarking surveys and maintenance performance guidelines.
Precision Maintenance is talked about in many companies and implemented at many companies, many with great success, however most companies do not understand Precision Maintenance. In this paper I will clear up some misconceptions and untruths concerning it.
The document discusses best maintenance repair practices and identifies issues that commonly prevent organizations from following them. It finds that 70% of equipment failures are self-induced due to maintenance personnel not knowing or following basic maintenance practices. Surveys showed over 90% of maintenance personnel lacked complete mechanical maintenance fundamentals. The document outlines best practices such as taking a proactive rather than reactive approach, ensuring maintenance personnel have requisite skills, and providing discipline and direction to follow practices. It recommends organizations identify whether issues exist, determine the causes, provide training to change maintenance culture, and develop a proactive maintenance strategy to implement changes and measure financial gains from following best practices.
Advanced Maintenance And Reliability (Best Maintenance and Reliability Practi...Ricky Smith CMRP, CMRT
Maintenance and reliability has taken great strides toward managing asset reliability by applying known best practices in maintenance and reliability finding that they can optimize reliability and reduce total cost and reduce risk by applying known best practices. However, if not most organizations are still trapped in the old way of thinking. Read this article and see where you stand.
Most companies don’t measure mean time between failures (MTBF), even though it’s the most basic measurement that quantifies reliability. MTBF is the average time an asset functions before it fails. So, why don’t they measure MTBF? Let’s define reliability first before we go any further.
Reliability: The ability of an item to perform a required function under stated conditions for a stated period of time
So why don’t we measure Mean Time Between Failure. This articles discusses this issue.
The concepts contained within Lean Manufacturing are not limited merely to production systems. These concepts translate directly into the world of maintenance and reliability.
At the core of Lean Manufacturing philosophy is the concept of elimination of waste. It is about getting precisely the right resources to precisely the right place and at the right time to make only the necessary products in the most efficient manner possible.
The concepts of the elimination of waste can be easily traced to Benjamin Franklin. Poor Richard encouraged the concepts of elimination of waste in numerous ways. Adages like “Waste not, want not”, “A penny
saved is two pence clear…Save and have” and “He that idly loses 5s. [shillings] worth of time, loses 5s., and might as prudently throw 5s. into the river.” Yes, it was Benjamin Franklin that educated us about the possibility that avoiding unnecessary costs could return more profit than simply increasing total sales.
It was Henry Ford who took the concept of the elimination of waste and integrated it into daily operations at his manufacturing facilities. Mr. Ford’s attitude can be seen in his books, “My Life and Work” (1922) and in “Today and Tomorrow” (1926) where he describes the folly of waste and introduces the world to Just-In-Time manufacturing. Mr. Ford cites inspiration from Benjamin Franklin as part of the foundation of these concepts.
However, it wasn’t until Toyota’s Chief Engineer, Taiichi Ohno systematized these concepts and the concept of pull (Kanban) into the Toyota Production System and created a cohesive production philosophy that was focused on the elimination of waste, that the world was able to see the real power of Lean Manufacturing. Interestingly enough, when Mr. Ohno was asked about the inspiration of his system, he merely laughed and said he read most of it in Henry Ford’s book.
Part 1 of this report will focus on one very specific Lean Manufacturing method known as 5S. This section will detail how a 5S initiative focusing on a plant’s Preventive Maintenance (PM) Program can immediately unlock resources within that maintenance department and make the PM process significantly more effective and efficient. Part 2 will look at the Deadly Wastes (Muda) of manufacturing and how elimination of these wastes is also a focus of the reliability process. Part 3 will discuss the overall objectives of Lean Manufacturing and parallel them with the overall objectives of the reliability process. Part 4 will discuss Poka- Yoke (mistake proofing) and see how several standard maintenance techniques are, in fact, Poka-Yoke techniques. A brief discussion of Kaizen and how both Lean Manufacturing and Maintenance and Reliability initiatives share these very same goals and objectives will summarize the entire report.
10 Things an Operations Supervisor can do Today to Improve ReliabilityRicky Smith CMRP, CMRT
Continuing the series that started with maintenance technicians and supervisors, if you are new to the position of Operations Supervisor, what are some of the things you can begin working on immediately to improve reliability within the area you work?
This document outlines the fundamentals of an effective maintenance program. It discusses key aspects such as viewing maintenance as part of the manufacturing process, having clear roles and responsibilities, keeping equipment clean, using a maintenance management system to track work, developing maintenance strategies based on equipment criticality and failure modes, fixing breakdowns quickly using problem analysis, and ensuring maintenance staff have high skills and perform quality work.
Glossary. Maintenance and Reliability Body of KnowledgeEliezer Jimenez
This document defines terms related to asset and equipment maintenance management. It defines terms like achieved availability, active work order, annual maintenance cost, corrective maintenance, and preventive maintenance. It provides formulas for metrics like achieved availability and discusses maintenance organization structures like centralized and decentralized models. The document is intended to define terms used for benchmarking surveys and maintenance performance guidelines.
Precision Maintenance is talked about in many companies and implemented at many companies, many with great success, however most companies do not understand Precision Maintenance. In this paper I will clear up some misconceptions and untruths concerning it.
The document discusses the importance of including equipment operators in Reliability Centered Maintenance (RCM) analysis. Operators play a key role by identifying important failure modes that others may overlook related to equipment operation. They can provide valuable details in failure effect statements about process impacts. Operators also help determine downtime from failures and identify mitigation tasks, such as process monitoring, that are effective at improving reliability. The document argues that excluding operators results in an incomplete RCM analysis.
Most companies spend a lot of money training their maintenance personnel to troubleshoot a hydraulic system.
If we focused on preventing system failure then we could spend less time and money on troubleshooting a hydraulic system. We normally except hydraulic system failure rather than deciding not to except hydraulic failure as the norm. Let’s spend the time and money to eliminate hydraulic failure rather than preparing for failure.
Using Safety to Drive Lean ImplementationPhil La Duke
Using safety to drive lean implementation can help organizations gain competitive advantages through greater efficiency while eliminating waste. Implementing lean tools such as standard work, visual management, and empowering workers to stop production for safety issues can simultaneously make workplaces safer and more productive. Many actions that make work safer, such as error proofing equipment and processes, also make operations leaner. Viewing safety as a way to reduce costs from injuries and as a leading indicator of lean implementation can provide benefits across quality, production, and costs.
Preventive Maintenance - Actions performed on a time- or machine-run-based schedule that detect, preclude, or mitigate degradation of a component or system with the aim of sustaining or extending its useful life through controlling degradation to an acceptable level. (Definition Source: SMRP Best Practices)
Reliability Centered Maintenance (RCM) is a proven, logical, sensible approach that helps companies improve reliability. Yet most companies are not getting the return they expected. They see RCM as too much trouble for too little reward. So that’s why we decided to publish this new report. Find out why RCM doesn't work, what needs to change and how to put RCM to work at your company so it doesn't become another Resource Consuming Monster.
We know RCM works however I wanted to share with you the 5 Biggest Mistakes people make using Reliability Centered Maintenance. Love to hear your comments or tell us what you have seen work and not work.
The document outlines the daily activities of an effective proactive maintenance manager, including:
1) Meeting with maintenance supervisors and production managers to review KPIs and address any issues from the past 24 hours;
2) Reviewing maintenance KPI dashboards to monitor performance indicators;
3) Conducting plant visits and crew meetings to ensure work is being completed properly;
4) Guiding the maintenance organization through leadership, organization, and management principles focused on continuous improvement.
Maintenance Skills Training for industry is a hot subject right now. In many areas of the country, companies are competing for skilled maintenance personnel.
“A Deloitte study found that the skills gap may leave an estimated 2.4 million positions unfilled between 2018 and 2028, with a potential economic impact of $2.5 trillion”
The skill level of the maintenance personnel in most companies is well below what industry would say is acceptable. In the past, I have been involved with the assessment of the skill level for hundreds of maintenance personnel in the U.S. and Canada and found 80% of the people assessed scored less than 50% of where they need to be in the basic technical skills to perform their jobs. The literacy level of maintenance personnel is also a problem. In some areas of the United States we find that up to 40% of maintenance personnel in a plant are reading below the eighth grade level. After performing the Gunning FOG index, we find the reading level for mechanical maintenance personnel should be the twelfth year level and electrical maintenance personnel the fourteenth year level (associate degree).
1. The document discusses operational excellence and how safety is a key part of achieving it. Safety eliminates waste from injuries and downtime and helps drive continuous improvement.
2. Tools for achieving operational excellence like eliminating waste, improving equipment reliability, standard work, and visual management all help improve safety as well as efficiency.
3. Tracking safety metrics and managing safety using data helps identify issues and drive organizational change for both safety and productivity gains. Maintaining safety is important for cost reduction and achieving operational excellence.
The document provides recommendations for preparing for the CMRP exam, including joining SMRP, participating in chapters and special interest groups, studying recommended books and materials from the SMRP website, and taking practice exams. It emphasizes studying the SMRP Body of Knowledge, metrics, best practices, and GFMAM Asset Management Landscape. On the day before the exam, it recommends limiting alcohol, studying in sessions with breaks, and getting sufficient sleep.
This document outlines the key knowledge, skills, and responsibilities required of proactive maintenance technicians. It discusses topics like maintenance best practices, preventive and predictive maintenance, planning and scheduling, execution, safety compliance, technical knowledge, and leadership. The document emphasizes that technicians should have defined roles and responsibilities, follow repeatable processes, and use metrics to monitor performance and drive improvement. Overall, it provides a comprehensive overview of the requirements to be a successful proactive maintenance technician.
This document provides an evaluation of preventative technologies for Kangaroo Inc., a dental software company. It identifies the top risks as patching, outdated firewalls, BYOD, backup failures, and lack of change control. A failure modes and effects analysis identifies patching as a major risk due to staff turnover and system diversity. The outdated firewall lacks vendor support and regional offices have expired intrusion detection. Recommendations are provided to reduce residual risks through improved patching, new firewalls, BYOD policies, backup solutions, and change control procedures.
Top Tips for Improving your Quality ManagementClaire Healey
An essential guide to assist you, the Quality Expert in enforcing the standards you expect on a daily basis across the whole manufacturing plant. Improve product quality, traceability and Statistical Process Control (SPC) whilst preventing mix-up and product recalls in manufacturing.
The 7 deadly sins of Overall Equipment Effectiveness (OEE)Claire Healey
OEE projects often fail due to common pitfalls. These "7 deadly sins" include viewing OEE as only a technical project, focusing on the software alone rather than continuous improvement, making the process too complex, having unrealistic expectations of rapid gains, failing to properly trial systems, lacking buy-in across the organization, and selecting the wrong OEE solution provider. To succeed, it is important to keep goals focused on business priorities, gain cultural support, start simply and grow solutions over time, and partner with a provider committed to measurable improvements.
A proactive maintenance technician is a highly trained professional who is an expert in his or her skills area, has knowledge of other skills areas, including safety and production, and has a desire to learn more. This professional knows and can
implement a failure-modes driven maintenance strategy for any piece of equipment.
A proactive maintenance technician uses knowledge and experience to ensure the maintenance process is optimized by making constructive recommendations to
management concerning improvement areas.
To ensure success, a proactive maintenance technician is proactive in everything he or she does. This person constantly reviews information to ensure procedures are accurate and issues are resolved quickly and does what is required to ensure the work is repeatable. Such a professional leads by example and takes responsibility for training new employees on how to be a proactive and effective maintenance technician.
Introduction to Failure Mode and Effects Analysis (FMEA) in TQMDr.Raja R
This document provides an introduction to Failure Mode and Effects Analysis (FMEA). It discusses what FMEA is, the types of FMEA (Design and Process), why FMEA is performed, when to perform it, and the steps to perform an FMEA. FMEA is a systematic method to identify potential failures, assess risks, and mitigate issues in the design or manufacturing process. It involves identifying failure modes and their causes and effects, then prioritizing failures based on severity, occurrence, and detection rankings. The goal is to address high-risk failures early in the design or process development stages to reduce costs and improve quality and safety.
The document discusses several fundamental concepts related to industrial safety and the environment. It outlines the Pareto principle, also known as the 80/20 rule, which states that typically 80% of the effects come from 20% of the causes. For example, 20% of hazards may cause 80% of injuries. It also discusses management error and how 85% of errors may be due to poor management processes rather than worker issues. Finally, it introduces the six sigma approach which uses a five-step DMAIC process of define, measure, analyze, improve, and control to identify and address issues in processes.
Reliability Centered Maintenance (RCM) is a logical approach developed in the 1960s that helps companies improve equipment reliability by determining potential failure modes and maintenance plans. RCM analyzes a system's functions, potential failures, and failure effects to develop a maintenance plan. Implementing RCM increases maintenance effectiveness by ensuring the right type and frequency of maintenance, and increases efficiency by comparing maintenance costs to equipment downtime costs. RCM also provides benefits like upskilling maintenance technicians and operators through cross-training on equipment operation and failure analysis.
Maintenance Planning and Scheduling is critical to success of any Maintenance Organization resulting in a significant increase in Wrench-time (Hands on Tool Time). Planning and Scheduling are two distinct functions which are dependent on each other.
Automated OEE data collection systems remove the inaccuracies, inefficiencies and bias of manual data collection and data entry, enabling manufacturers to more reliably collect important production data needed to make operational decisions. Production tracking software systems, like ShopFloorConnect, track uptime, downtime, the reasons for downtime, production rate, and piece part counts (when applicable). Running an automated shop floor data collection system is like having a team of manufacturing engineers doing a detailed efficiency study of the entire factory - all the time.
The document discusses how adopting a preventive maintenance mindset can help avoid costly equipment failures and downtime. It recommends shifting from a reactive "fix-it-when-it's-broken" strategy to a preventive strategy of scheduled maintenance check-ups. A preventive strategy can reduce maintenance costs by 40% and downtime by 50% by identifying issues before they cause problems. The document provides tips for creating a preventive maintenance mindset, including implementing total productive maintenance practices, being prepared for failures, scheduling regular maintenance checks, and ensuring adequate resources.
This document outlines the most common mistakes made in containment plans. It discusses that containment plans should involve all stakeholders from the beginning to ensure a clear scope of work. It also notes that inconsistent training methods between experienced and new workers can lead to quality issues. Finally, it stresses that containment is not the final solution, and that the right approach can reduce recurrence and get production back on track faster while also helping prevent future disruptions.
The document discusses the importance of including equipment operators in Reliability Centered Maintenance (RCM) analysis. Operators play a key role by identifying important failure modes that others may overlook related to equipment operation. They can provide valuable details in failure effect statements about process impacts. Operators also help determine downtime from failures and identify mitigation tasks, such as process monitoring, that are effective at improving reliability. The document argues that excluding operators results in an incomplete RCM analysis.
Most companies spend a lot of money training their maintenance personnel to troubleshoot a hydraulic system.
If we focused on preventing system failure then we could spend less time and money on troubleshooting a hydraulic system. We normally except hydraulic system failure rather than deciding not to except hydraulic failure as the norm. Let’s spend the time and money to eliminate hydraulic failure rather than preparing for failure.
Using Safety to Drive Lean ImplementationPhil La Duke
Using safety to drive lean implementation can help organizations gain competitive advantages through greater efficiency while eliminating waste. Implementing lean tools such as standard work, visual management, and empowering workers to stop production for safety issues can simultaneously make workplaces safer and more productive. Many actions that make work safer, such as error proofing equipment and processes, also make operations leaner. Viewing safety as a way to reduce costs from injuries and as a leading indicator of lean implementation can provide benefits across quality, production, and costs.
Preventive Maintenance - Actions performed on a time- or machine-run-based schedule that detect, preclude, or mitigate degradation of a component or system with the aim of sustaining or extending its useful life through controlling degradation to an acceptable level. (Definition Source: SMRP Best Practices)
Reliability Centered Maintenance (RCM) is a proven, logical, sensible approach that helps companies improve reliability. Yet most companies are not getting the return they expected. They see RCM as too much trouble for too little reward. So that’s why we decided to publish this new report. Find out why RCM doesn't work, what needs to change and how to put RCM to work at your company so it doesn't become another Resource Consuming Monster.
We know RCM works however I wanted to share with you the 5 Biggest Mistakes people make using Reliability Centered Maintenance. Love to hear your comments or tell us what you have seen work and not work.
The document outlines the daily activities of an effective proactive maintenance manager, including:
1) Meeting with maintenance supervisors and production managers to review KPIs and address any issues from the past 24 hours;
2) Reviewing maintenance KPI dashboards to monitor performance indicators;
3) Conducting plant visits and crew meetings to ensure work is being completed properly;
4) Guiding the maintenance organization through leadership, organization, and management principles focused on continuous improvement.
Maintenance Skills Training for industry is a hot subject right now. In many areas of the country, companies are competing for skilled maintenance personnel.
“A Deloitte study found that the skills gap may leave an estimated 2.4 million positions unfilled between 2018 and 2028, with a potential economic impact of $2.5 trillion”
The skill level of the maintenance personnel in most companies is well below what industry would say is acceptable. In the past, I have been involved with the assessment of the skill level for hundreds of maintenance personnel in the U.S. and Canada and found 80% of the people assessed scored less than 50% of where they need to be in the basic technical skills to perform their jobs. The literacy level of maintenance personnel is also a problem. In some areas of the United States we find that up to 40% of maintenance personnel in a plant are reading below the eighth grade level. After performing the Gunning FOG index, we find the reading level for mechanical maintenance personnel should be the twelfth year level and electrical maintenance personnel the fourteenth year level (associate degree).
1. The document discusses operational excellence and how safety is a key part of achieving it. Safety eliminates waste from injuries and downtime and helps drive continuous improvement.
2. Tools for achieving operational excellence like eliminating waste, improving equipment reliability, standard work, and visual management all help improve safety as well as efficiency.
3. Tracking safety metrics and managing safety using data helps identify issues and drive organizational change for both safety and productivity gains. Maintaining safety is important for cost reduction and achieving operational excellence.
The document provides recommendations for preparing for the CMRP exam, including joining SMRP, participating in chapters and special interest groups, studying recommended books and materials from the SMRP website, and taking practice exams. It emphasizes studying the SMRP Body of Knowledge, metrics, best practices, and GFMAM Asset Management Landscape. On the day before the exam, it recommends limiting alcohol, studying in sessions with breaks, and getting sufficient sleep.
This document outlines the key knowledge, skills, and responsibilities required of proactive maintenance technicians. It discusses topics like maintenance best practices, preventive and predictive maintenance, planning and scheduling, execution, safety compliance, technical knowledge, and leadership. The document emphasizes that technicians should have defined roles and responsibilities, follow repeatable processes, and use metrics to monitor performance and drive improvement. Overall, it provides a comprehensive overview of the requirements to be a successful proactive maintenance technician.
This document provides an evaluation of preventative technologies for Kangaroo Inc., a dental software company. It identifies the top risks as patching, outdated firewalls, BYOD, backup failures, and lack of change control. A failure modes and effects analysis identifies patching as a major risk due to staff turnover and system diversity. The outdated firewall lacks vendor support and regional offices have expired intrusion detection. Recommendations are provided to reduce residual risks through improved patching, new firewalls, BYOD policies, backup solutions, and change control procedures.
Top Tips for Improving your Quality ManagementClaire Healey
An essential guide to assist you, the Quality Expert in enforcing the standards you expect on a daily basis across the whole manufacturing plant. Improve product quality, traceability and Statistical Process Control (SPC) whilst preventing mix-up and product recalls in manufacturing.
The 7 deadly sins of Overall Equipment Effectiveness (OEE)Claire Healey
OEE projects often fail due to common pitfalls. These "7 deadly sins" include viewing OEE as only a technical project, focusing on the software alone rather than continuous improvement, making the process too complex, having unrealistic expectations of rapid gains, failing to properly trial systems, lacking buy-in across the organization, and selecting the wrong OEE solution provider. To succeed, it is important to keep goals focused on business priorities, gain cultural support, start simply and grow solutions over time, and partner with a provider committed to measurable improvements.
A proactive maintenance technician is a highly trained professional who is an expert in his or her skills area, has knowledge of other skills areas, including safety and production, and has a desire to learn more. This professional knows and can
implement a failure-modes driven maintenance strategy for any piece of equipment.
A proactive maintenance technician uses knowledge and experience to ensure the maintenance process is optimized by making constructive recommendations to
management concerning improvement areas.
To ensure success, a proactive maintenance technician is proactive in everything he or she does. This person constantly reviews information to ensure procedures are accurate and issues are resolved quickly and does what is required to ensure the work is repeatable. Such a professional leads by example and takes responsibility for training new employees on how to be a proactive and effective maintenance technician.
Introduction to Failure Mode and Effects Analysis (FMEA) in TQMDr.Raja R
This document provides an introduction to Failure Mode and Effects Analysis (FMEA). It discusses what FMEA is, the types of FMEA (Design and Process), why FMEA is performed, when to perform it, and the steps to perform an FMEA. FMEA is a systematic method to identify potential failures, assess risks, and mitigate issues in the design or manufacturing process. It involves identifying failure modes and their causes and effects, then prioritizing failures based on severity, occurrence, and detection rankings. The goal is to address high-risk failures early in the design or process development stages to reduce costs and improve quality and safety.
The document discusses several fundamental concepts related to industrial safety and the environment. It outlines the Pareto principle, also known as the 80/20 rule, which states that typically 80% of the effects come from 20% of the causes. For example, 20% of hazards may cause 80% of injuries. It also discusses management error and how 85% of errors may be due to poor management processes rather than worker issues. Finally, it introduces the six sigma approach which uses a five-step DMAIC process of define, measure, analyze, improve, and control to identify and address issues in processes.
Reliability Centered Maintenance (RCM) is a logical approach developed in the 1960s that helps companies improve equipment reliability by determining potential failure modes and maintenance plans. RCM analyzes a system's functions, potential failures, and failure effects to develop a maintenance plan. Implementing RCM increases maintenance effectiveness by ensuring the right type and frequency of maintenance, and increases efficiency by comparing maintenance costs to equipment downtime costs. RCM also provides benefits like upskilling maintenance technicians and operators through cross-training on equipment operation and failure analysis.
Maintenance Planning and Scheduling is critical to success of any Maintenance Organization resulting in a significant increase in Wrench-time (Hands on Tool Time). Planning and Scheduling are two distinct functions which are dependent on each other.
Automated OEE data collection systems remove the inaccuracies, inefficiencies and bias of manual data collection and data entry, enabling manufacturers to more reliably collect important production data needed to make operational decisions. Production tracking software systems, like ShopFloorConnect, track uptime, downtime, the reasons for downtime, production rate, and piece part counts (when applicable). Running an automated shop floor data collection system is like having a team of manufacturing engineers doing a detailed efficiency study of the entire factory - all the time.
The document discusses how adopting a preventive maintenance mindset can help avoid costly equipment failures and downtime. It recommends shifting from a reactive "fix-it-when-it's-broken" strategy to a preventive strategy of scheduled maintenance check-ups. A preventive strategy can reduce maintenance costs by 40% and downtime by 50% by identifying issues before they cause problems. The document provides tips for creating a preventive maintenance mindset, including implementing total productive maintenance practices, being prepared for failures, scheduling regular maintenance checks, and ensuring adequate resources.
This document outlines the most common mistakes made in containment plans. It discusses that containment plans should involve all stakeholders from the beginning to ensure a clear scope of work. It also notes that inconsistent training methods between experienced and new workers can lead to quality issues. Finally, it stresses that containment is not the final solution, and that the right approach can reduce recurrence and get production back on track faster while also helping prevent future disruptions.
The document discusses key aspects of effective maintenance management, including defining goals, developing strategies and plans, creating schedules, and allocating resources. It emphasizes that maintenance should be viewed as a business that supports organizational goals and profitability. Effective maintenance management requires considering maintenance a strategic investment rather than just an expense.
The document discusses various aspects of maintenance management policies, including:
1. Policies around work allocation, such as determining the appropriate level of scheduling, selection of jobs to schedule, and balancing preventive and breakdown maintenance.
2. Policies regarding the workforce, including deciding whether to use an in-house workforce or outside contractors, and factors to consider in that decision.
3. General policies cover areas like interplant relations and control of the maintenance function.
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This white paper discusses the importance of procedure based maintenance in facilities. It argues that relying only on the skills and experience of maintenance staff can lead to failures and inconsistencies. Effective, repeatable procedures are needed to ensure safety, reliability, and sustainable results. The paper recommends making staff aware of issues, training them on procedures, implementing procedures, continuously improving, and monitoring results. Procedure based maintenance can help reduce variation and human error.
“My maintenance staff is highly trained and do not like using procedures.” If the statement is valid, and the cost of asset failure is not important to our operation, then your staff must have an unlimited and infallible memory – congratulations!
Did you know that the most complex equipment ever built was a nuclear submarine and that the first nuclear submarines experienced failures due to lack of effective procedures, thus ending in catastrophic failure?
If safety is number one in your organization, then repeatable, effective work procedures should be as well.
Why is Equipment Maintenance Important.pdfTomBrooks39
In the fast-paced world of industries, the heartbeat of any operation lies in well-maintained equipment. Let's delve into why equipment maintenance is crucial, unraveling the layers of benefits that come with it. Ever wondered why your car needs regular check-ups? It's the same principle that applies to the complex machinery driving industries. Equipment maintenance is about keeping things running smoothly, preventing unexpected breakdowns, and saving you from hefty repair bills.
Ways on how to improve manufacturing operationsSameerShaik43
Smarter Contact has evolved the way businesses connect with customers and prospects through its innovative and easy-to-use SMS marketing platform. However, behind it is a backstory, a long history of determination as an immigrant to the US to a company that employs 30+ people around the world.
https://www.tycoonstory.com/tips/how-to-improve-manufacturing-operations/
THE LUBRICATION RELIABILITY WINNERWHEEL BOOKLETEnluse B.V.
THE LUBRICATION RELIABILITY WINNERWHEEL BOOKLET
10 ways to improve your Lubrication Reliability™ Program
Key factor of a World Class Maintenance Organization is the Lubricant Management. While Lubrication has for a long time been seen as “another-job-to-do”, today a modern Lubrication Reliability Program is the only answer. Read more about it in this free 67 page "LR-WinnerWheel"booklet.
https://sites.google.com/view/lustor/lubrication-reliability
This document provides an overview of Total Productive Maintenance (TPM). It defines TPM as a productive maintenance approach implemented by all employees in an organization to improve equipment effectiveness. The key points covered include: TPM was developed in Japan in the 1950s and involves operators and management in continuous equipment improvement; the goals of TPM are to increase production quality and job satisfaction through cross-functional teamwork; and TPM utilizes methods like overall equipment effectiveness (OEE) and autonomous maintenance.
Preventive maintenance programs that rely solely on time-based tasks are often ineffective and result in high equipment failure rates. Research shows over 80% of failures are not related to age or use. To improve reliability, the author migrated to a proactive approach focusing on asset health monitoring to determine maintenance needs. This approach identifies specific failure modes and uses predictive technologies to catch issues early. The result is significantly reduced failures and improved reliability, availability, and cost savings. Sharing successes from pilot programs encourages management support to roll out the approach for all critical assets.
In the Nanoprecise, industrial preventative maintenance is a crucial aspect of ensuring the smooth operation and longevity of your machinery. Finally, by investing in proper preventive maintenance, you can save money in the long run while increasing overall production output. So don't wait any longer; start implementing these tips today!
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The document discusses various types of maintenance including preventive, corrective, condition-based, predictive, reliability-centered, and value driven maintenance. It explains that preventive maintenance involves maintaining equipment before failures occur to prevent downtime and costs, while corrective maintenance repairs equipment after failures. Condition-based maintenance uses indicators to determine when equipment will fail and prioritizes maintenance. Predictive techniques help determine equipment condition to schedule maintenance. Reliability-centered maintenance aims to improve cost-effectiveness and uptime. The 5S methodology focuses on effective workplace organization through sorting, setting in order, shining, standardizing, and sustaining these practices.
The document describes a process called PM Optimisation (PMO) for improving maintenance programs. PMO aims to rationalize preventive maintenance tasks by identifying useless or duplicative tasks. It is a more efficient alternative to Reliability Centered Maintenance for mature assets. PMO involves compiling existing maintenance tasks, analyzing failure modes, evaluating consequences of failures, and determining optimized maintenance policies. Applying PMO can eliminate 40-60% of unnecessary tasks and improve asset performance and productivity.
Much has been written about lean manufacturing and the lean enterprise—enough that nearly all readers are familiar with the concepts as well as the phrases themselves. But what about lean maintenance?
Is it merely a subset of lean manufacturing? Is it a natural fall-in-behind spinoff result of adopting lean manufacturing practices?
Much to the chagrin of many manufacturing companies, whose attempts at implementing lean practices have failed ignominiously, lean maintenance is neither a subset nor a spinoff of lean manufacturing. It is instead a prerequisite for success as a lean manufacturer. This article will explain why.
Total Productive Maintenance: A Comprehensive Guide | Enterprise WiredEnterprise Wired
Here are some pillars of Total Productive Maintenance: 1. Initial Setup (5S), 2. Planned Maintenance, 3. Autonomous Maintenance, 4. Quality Maintenance, 5. Early Management of Equipment Defects.
1) The document discusses implementing a condition-based monitoring program for mechanical assets at power plants to improve reliability. It recommends transitioning from reactive maintenance to using continuous monitoring and automation.
2) It outlines a 3-step process: prioritizing critical assets, applying continuous condition monitoring technologies, and analyzing data to evaluate asset health and detect problems early.
3) The document provides examples of common asset failure modes and recommends monitoring pumps, fans, and other rotating equipment in addition to turbines to improve availability.
Precision Maintenance is talked about in many companies and implemented at many companies, many with great success, however most companies do not understand Precision Maintenance. In this paper I will clear up some misconceptions and untruths concerning it.
Similar to Lubrication linked with a maintenance strategy (20)
Over a few years, increasing interest is seen in food-grade lubricants for the machines operating in the pharmaceutical industry. Mosil provides Specialty Lubricants for Pharma Industry
Bearing Lubrication is an essential process in order to reduce friction as well as for the proper function of bearings. Let's discuss some myths related to bearing lubrication.
Ideal characteristics for choosing electrical component cleanerMosil Lubricants
Cleaning electrical components is important to remove contaminants and lubricants help protect machinery. Selecting the right electrical component cleaner is important to consider characteristics like having a high dielectric strength to prevent electric shock, being non-flammable for safety around sparks or flames, and being non-corrosive and compatible with metals, plastics, and rubbers used in components. It is also good for cleaners to have a residue-free and high evaporation rate formulation.
Appropriate lubrication is an important factor to be considered in Industrial Maintenance. Without proper lubrication systems, many industrial and manufacturing processes would wear down from friction, overheating etc.
Lubrication is vital for bearings and affects their life and the life of machinery. Proper lubrication reduces friction, wear, and improves the life of bearings. Bearings must be lubricated at the appropriate interval with the correct amount and type of grease. Incompatible grease, loss of lubricant from overheating or incorrect greasing, and excess lubrication can lead to bearing failure and equipment downtime. Following proper procedures for re-greasing, including cleaning, using the correct grease, adding the recommended amount, and cleaning up afterwards, can help ensure healthy bearings and equipment.
MOSIL’s product basket has number of lubricating products which meets the food grade standards, NSF approvals for any kind of incidental contact of in-process products with the lubricants
1. Mosil DW-6294 is a specialty wax type corrosion protection coating for medium to long term indoor and outdoor protection of components.
2. It leaves a dry waxy film capable of withstanding severe moisture and humidity for up to 24 months of protection against rust and corrosion.
3. The product can be applied by brush or dipping to components in oil exploration equipment, machinery, structural steel, and for overseas shipments or storage of farm equipment.
The document is a product bulletin from Mosil Lubricants Private Limited describing their product MOSIL SN-12, a synthetic grease. It is a multifunctional silicone grease compounded from fortified silicone oil thickened with a special lithium soap and EP additives, making it suitable for high speed and high temperature applications. It provides benefits such as being a lifelong lubricant, operating under extremes of speed and temperature, being water repellent and chemically inert. The grease is ideal for applications such as ball and roller bearings, sleeve bearings, needle bearings, steam joints, submersible pump bearings, water turbines, and more.
MOSIL SN-5120 is a premium high temperature grease formulated with a synthetic ester base oil and lithium complex soap thickener. It is designed for applications requiring high temperatures such as oven conveyors and defense equipment. The grease provides effective lubrication from -35°C to 220°C and has benefits such as excellent oxidation resistance, protection from rust and corrosion, and a long service life. It is available in 1 kg jars, 20 kg pails, and 180 kg drums.
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Understanding Catalytic Converter Theft:
What is a Catalytic Converter?: Learn about the function of catalytic converters in vehicles and why they are targeted by thieves.
Why are They Stolen?: Discover the valuable metals inside catalytic converters (such as platinum, palladium, and rhodium) that make them attractive to criminals.
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Parking Strategies: Tips on where and how to park your vehicle to reduce the risk of theft, such as parking in well-lit areas or secure garages.
Protective Devices: Overview of various anti-theft devices available, including catalytic converter locks, shields, and alarms.
Etching and Marking: The benefits of etching your vehicle’s VIN on the catalytic converter or using a catalytic converter marking kit to make it traceable and less appealing to thieves.
Surveillance and Monitoring: Recommendations for using security cameras and motion-sensor lights to deter thieves.
Statistics and Insights:
Theft Rates by Borough: Analysis of data to determine which borough in NYC experiences the highest rate of catalytic converter thefts.
Recent Trends: Current trends and patterns in catalytic converter thefts to help you stay aware of emerging hotspots and tactics used by thieves.
Benefits of This Presentation:
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Local Insights: Understand the specific risks in different NYC boroughs, helping you take targeted preventive measures.
This presentation aims to equip you with the knowledge and tools needed to protect your vehicle from catalytic converter theft, ensuring you are prepared and proactive in safeguarding your property.
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Lubrication linked with a maintenance strategy
1. Regular Maintenance is frequently considered as an evil
necessity and often delayed or canceled to meet production
demands. Taking equipment out of service to improve
functionality can be a tough call, especially if the only
maintenance activity is lubrication. As the industry has evolved,
so have the practices and philosophies for how and when to
perform maintenance and lubrication. More options and tools
are now available to guide the actions of personnel for nearly all
lubrication tasks. However, to truly understand how this
evolution has changed the landscape, you must know where
maintenance began and where it is today.
In a lubrication program, there are tasks for applying lubricants, analyzing their state, and
eventually disposing of them once they reach the end. Beyond these front-line tasks are management
activities to ensure work is completed properly. Perhaps the simplest lubrication task involves the use
of a grease gun. However, these devices have been improved in recent years and now incorporate
advanced technology. Before utilizing a grease gun, be sure to consider the task in relation to the
different maintenance philosophies discussed previously.
This same methodology applies to oil applications. While you may rely on the rotating motion of a
machine to apply oil to various internal components, you control many other factors that can provide an
indication of success. The workload will vary greatly depending on the mindset of the individual or
organization.
LUBRICATION LINKED WITH
A MAINTENANCE STRATEGY
UNDERSTANDING THE LINK
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Failure Detection
Fault isolation and measures to act over.
Corrective action on faults.
Operational verification
Maintenance is required if the machine fails to satisfy the
minimum level of specification performance and is optional if
the partially failed machine still satisfies the minimum level of
specification performance.
Industrial Maintenance broadly takes place in four phases.
LUBRICATION ACTIVITIES
MAINTENANCE BELIEFS
2. Most people are familiar with the term “reactive maintenance.” This
approach involves repairing machines only after a breakdown or failure. Too
often, reactive philosophies are adopted by organizations that are short on the
manpower or stuck in the “that’s how we’ve always done it” mentality. This
leads to overblown maintenance budgets, poor operational performance, and
a staff that is constantly firefighting. As someone who worked in a reactive
mode for years, I can attest to the stress it puts on your team. For instance, it
was difficult to know when you were going home each day, if at all. Even on
weekends or holidays, there was always the risk of being called into work. This
maintenance philosophy is not sustainable and has largely been relegated to
non-critical or small pieces of equipment.
In an effort to move away from the reactive state and in cases where safety
is paramount, planned or scheduled maintenance was implemented. Known as
preventive maintenance, this approach entails having a set period or interval
when maintenance is scheduled and then performed. The airline industry
provides a good example of this philosophy. Running an airplane engine until
failure is not an option because of the safety ramifications. Therefore,
maintenance is scheduled based on the number of hours or flights. The same
practice was adopted in the industry. This included closely following
OEM recommendations or intervals to prevent a failure. You probably use a
similar method with your vehicle’s maintenance. By introducing a scheduling
component to your maintenance activities, you can add some direction and
continuity to a daily process.
Although preventive maintenance can help reduce the chaos of failures, it
can still result in high maintenance costs when good parts are replaced.
Reactive — An oil or grease sample is taken only after a potential problem is identified via a
sensory inspection.
Preventive — Routine samples are extracted, but the results are not analyzed.
Predictive — Good samples are obtained and analyzed, with the action taken on results from the
lab.
Proactive — New lubricants are sampled prior to service. Samples are taken from the right place,
in the right way, using the right tests and with the right interpretation strategy.
lubricant analysis falls into the realm of condition monitoring but can be used in various ways to
determine what is happening inside a mechanical system. It also can be divided into four different
strategies:
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LUBRICANT ANALYSIS STRATEGIES
PHILOSOPHY
3. More recently, new tools and accessories have become available to aid in equipment monitoring
and catching potential issues earlier. This monitoring of failure symptoms and faults is known as
predictive maintenance. The most common forms of this approach include using vibration analysis,
ultrasound, thermography, oil analysis, and a host of other technologies to provide an early warning of
an impending problem.
Predictive maintenance works well for machines that run continuously and often results in a
reduction of unplanned downtime. However, it usually comes with considerable upfront costs, not just
for the necessary tools but also in training the individuals who are expected to capture the pertinent
data. Diligence is required to ensure data is collected from the same place and in the same manner
each time. Inconsistent practices will skew the data and make it much more difficult to take
appropriate action.
Rather than fixing machines, proactive maintenance eliminates what causes them to fail. It can be
used to extend equipment life, as opposed to simply improving the process for repairs or identifying
when a machine is going to fail. Proactive maintenance focuses on the root causes of failure and
addresses them before they lead to an eventual problem. Much of proactive maintenance occurs
before a machine is ever turned on, including alignment and balancing. Without a proactive mindset,
equipment failures will continue to plague most maintenance departments. Analyzing what went
wrong and taking steps to prevent it from happening again are the hallmarks of being proactive.
Inspections are often ignored as the foundation of
a world-class lubrication program. Personnel who
walk by machines every day are the greatest source of
information to drive your program forward.
Greater emphasis must be placed on the
inspections, Just having a checklist or making simple
rounds is not enough. Digging deeper into what you
notice about the machine will be an extremely
valuable activity that will bear fruit in all aspects of
maintenance, regardless of the philosophy employed.
www.mosil.com
PHILOSOPHY
INFERENCE - NEVER IGNORE INSPECTIONS