Maintenance Excellence

Maintenance Excellence
Bernard Redmond (Director) ARM & Associates Ltd
Mob: 087‐3104712
Email: bredmond@armandassociates.co.uk

Agenda
 Who we are
 Clients
 What is Maintenance Excellence
 The need for Change
 Success stories
 Our Approach
Bernard Redmond | Mob: 087‐3104712 | Email: bredmond@armandassociates.co.uk

ARM & Associates Ltd
• Over 23 years in Maintenance Management consulting
Clients Activities
Sanofi Genzyme ‐ Waterford
Reliability Centred Maintenance
(RCM) Studies
Janssen Biologics ‐ Cork
DePuy (J&J) ‐ Cork
Sigma‐Aldrich (SAFC) ‐ Arklow
Astellas (Kerry)
PM Frequency Extension
Astellas (Dublin)
Astellas (Kerry) SAP Benchmarking Study

Doing the Right Maintenance at the Lowest Cost
What is Maintenance Excellence?

The Need for Change?
Internal and External Competition
Maintenance costs too high!
But we already have LEAN
LEAN is a Production process for reducing manufacturing
waste.
LEAN is not a Maintenance process. Instead it recommends
using other methodologies E.g. TPM, FMEA, RCM etc.
LEAN Maintenance Journey
No evidence of cost savings!
Still wasting time making all the mistakes, trying to figure out
what works and what doesn’t?

The Need for change ............ Cont.
Reliability Maintenance Engineer
Places additional strain on the maintenance budget.
Can have difficulty showing evidence of success!
Only gets involved after equipment has failed.
Fully Tied‐Up carrying out Root Cause Analysis (RCA)
Vibration Condition Monitoring Program not delivering any
real cost savings.
Doesn’t have enough time for TPM, FMEA, RCM, Criticality
etc
Operations dictate what they want him/her looked at …..

The Need for change
............ Cont.
Computerized Maintenance Management System (CMMS)
Adds to the overall cost of delivering maintenance.
Only being used to demonstrate PM schedule compliance to
Regulators.
Underutilized in the effort to drive Maintenance Excellence.
Often Maintenance Costs and
Downtime Costs are not recorded,
preventing the Total Cost of
Maintenance to be measured and
improved.
What gets measured gets changed

Our Approach to
Maintenance Excellence
Self‐funding
“Before you can spend money you have to save it”
PM Frequency Extension
 Analyze Work Order History for Failure Trends and MTBF
 Recommend extending PM Frequency where possible.
 Ours is a “No Win – No Fee” approach.
 Guaranteed cost savings; (we only get paid if recommendations are
approved by client).
 Requires login to CMMS
 Astellas Kerry Savings = 340% reduction in PM maintenance.
 Astellas Dublin Savings = 430% reduction in PM maintenance.
 Annual Savings range between €500 and €833 per PM.

Our Approach to Maintenance Excellence ….
Cont.
“Only apply rigorous maintenance optimization
methodologies to the critical few”
Carry out detailed System / Equipment Criticality Analysis.
For High Criticality carry our RCM studies.
 Apply RCM results to similar equipment (standardized SOP)

Reliability Centred Maintenance (RCM) Study
(1)
Work
(1)
Identify
Work
(2)
Work
(2)
Plan
Work
( )
Work
(3)
Schedule
Work
( )
Work
(4)
Execute
Work
(5)
Analyze
(6)
Improve
Identify Case Study Equipment / System
1. Selected by Company
2. ARM & Associates (Data Analysis)
One Day Site Visit
 Site Tour
 One to Ones with:
 CMMS Administrator
 Maintenance Manager, Supervisors and Technicians
 RCM Study Session (At Site)
 Follow‐up RCM sessions (Remotely facilitated using WebEx)
Equip Failure Data
 SAP
 PEMAC
 MAXIMO
 INFOR

Cont.
“Fully utilize CMMS capabilities”
Having a CMMS increases the overall cost of maintenance.
Carry out a CMMS Benchmarking Study to identify Effectiveness
and Efficiency gaps in the Work Management Process.
(1) Identification
(2) Planning
(3)
Scheduling
(4) Execute
Work
(5) Analyze Work
History
(6) Recommend
Improvements

Cont.
“Develop your existing resources as much as possible”
Sometimes organizations already have potential individuals in‐
house who could drive Maintenance Excellence.
All they need is easy access to professional Ad hoc Maintenance
Excellence, Mentoring and Coaching support.

eMentoring & Coaching
 Don’t know where or how to get started on your journey towards
Maintenance Best Practices.
 Wasting time making all the mistakes, trying to figure out what works
and what doesn’t?
 Wish you had an affordable way of accessing the professional help and
support you need.
 Want to receive the help and support you need at a time and place that
suits you.
 Want to be able to cancel the service at any time?
 Want to develop your career by becoming a Maintenance Best Practices
Champion?
LEAN TPM RCM FMEA
Condition
Monitoring
Training Reliability Availability Criticality

……….. cont
 Delivered through regular WebEx calls .
 No contract to sign. Cancel at any time.
 Applicable for Maintenance/Facilities Managers, Supervisors, Planners
and Reliability Engineers.
 Incudes CMMS training and template tools.
 Subjects covered include but are not limited to: ‐ Criticality
Assessments, LEAN Maintenance, TPM, RCM, FMEA, RCA, CMMS
Data & User Competency Benchmarking, PM reviews, Condition
Monitoring, Work Prioritisation, Competency Assessments and
Productivity Studies. Work Flow KPI development and monitoring etc.
LEAN TPM RCM FMEA
Condition
Monitoring
Training Reliability Availability Criticality

Maintenance Excellence

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