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Why is your current PM Program not Effective?
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Transcript of Why is your current PM Program not Effective?
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Why Preventive Maintenance Why Preventive Maintenance is not working for Youis not working for You
Presented by: Ricky Smith, CMRPJanuary 2011
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January, 2011
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Poll – Are current PMs Effective?
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Definition of Insanity
Doing the same thing over and over again andexpecting a different resultexpecting a different result
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Killer PMsEver heard of them?
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Without Proper PM Proactive Work is not achievable
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• 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 laserI l l b i ti l t i t• Improperly lubricating electric motors
• Not using a torque wrench• No Repeatable Procedures
PMsCM / RepairLubricationLubrication
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With these issues what do we have?
“High Variation in our Maintenance Process”
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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 Modes Driven
Strategy Driven Strategy
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Reduce Variation
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Variation in PM Compliance
10% Rule of PM
2 28 282 2 28
30 Day PM = Due in 3 daysy y
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“The significant problems we face cannot be solved with the same level of thinking we were solved with the same level of thinking we were at when we created them.”
- Albert Einstein
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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 .
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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
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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
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PF Curve
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I to P – PF Curve is not seen
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Failure Patterns
BathtubPattern A = 4%
Initial Break-in periodPattern D = 7%
W O tRandom
Pattern E = 14%
Time Time
Wear OutPattern B = 2%
Time Time
FatiguePattern C = 5% Infant Mortality
Pattern F = 68%
Age Related = 11% Random = 89%
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Source: John Moubray, Nowlan & Heap
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How to optimize your PM Program?
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Step 1: Educate Your Staff
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Educate Your Staff, Cont.
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Educate Yourself
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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.)
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Step 3: Perform a PM EvaluationPM Task ActionRecommendation # of Tasks % of Tasks Man-Hours
RepresentedNon-Value Added %Non Value Added (Delete) 1,640 8.2% 6,661
Reassign to Operator Care 1,380 6.9% 5,605
Reassign to LubeRoute 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 ModificationsRequired 2,487 10.4% 8,987
Totals 20,000 100.0% 87,297
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Step 4: Re-write your PMs focused on Failure Modes
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NOTE: Re-Write Your PMs so they are Repeatable
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Step 5: Begin measuring PM Effectiveness and Efficiency- Effectiveness: Mean Time Between Failure
- Efficiency: PM Compliance using the “10% Rule of PM”
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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
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“Excellence is a Habit”
- Aristotle, 330 BC
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Questions• Send your questions to [email protected]
• Tool Box Training Session are free and you can access them anytimey
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