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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 presentation I clear up some misconceptions and untruths concerning it.
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Copyright 2009 GPAllied©
Precision Maintenance“How to implement success?”
Presented by: Ricky Smith, CMRP
August 18, 2010
Copyright 2009 GPAllied©
Objectives
• Define what is Precision Maintenance
• What effect does it have on equipment reliability
• Define Best Practices in Precision Maintenance
• Required KPIs for Precision Maintenance
• Implementing a Successful Precision Maintenance
Program
• Traps you may find
Copyright 2009 GPAllied©
Precision Maintenance
• Precision Maintenance is a controlled experiment
conducted by skilled and discipline maintenance
personnel. The Objective is to optimize the life of an
asset with out failures.
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I-PF Curve
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A Failure Mode Driven Strategy
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Failure Modes Driven Strategy
• This your key to success is the prevention and prediction of
failures
• The Elimination of Self Induced Failures
• The Discipline to follow Processes and Procedures
• You must have all the right people on the bus or on in the right
seat
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Components of Precision Maintenance
#1 You must have Skilled Workers
• Assessment based on Knowledge and Skill
• Everyone attends all training
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Components of Precision Maintenance
#2 An Effective PM/PdM Program
#3 An Effective Planning Process
=
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A Failure Mode Driven Strategy
Copyright 2009 GPAllied©
Components of Precision Maintenance
#4 Effective Repeatable Procedures Developed and Executed
#5 Continuous Improvement – FRACAS (Failure Reporting, Analysis, and Corrective Action System)
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Components of Precision Maintenance
• FRACAS and Continuous Improvement
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Components of Precision Maintenance
• FRACAS Reports
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A Failure Mode Driven Strategy
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So, where do you begin?
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Make a Large Impact with Small Doses
Step 1 – Begin collection accurate data in your Maintenance Software
and track MTBF of a few critical assets / Post the results / talk to the
maintenance teams. I recommend implementing FRACAS at the same
time.
Copyright 2009 GPAllied©
Make a Large Impact with Small Doses
Step 2 – Hire someone from outside (yes outside your company) to
asses your lubrication practices and assist in the implementation
(check references, visit their customers)
Copyright 2009 GPAllied©
Make a Large Impact with Small Doses
Step 3 – Educate your people of a Failure Mode Strategy and implement
on your critical assets (call someone for help – don’t read a book)
Copyright 2009 GPAllied©
Time to Swallow the Pill
Step 4 – Perform an FMEA or RCM on Critical Equipment to develop
maintenance strategies focused on prevention or prediction of failure
modes. Write Repeatable and Effective Procedures for all new
maintenance strategies.
Caution: if you conduct this work yourself hire an outside expert on
Predictive Maintenance
Copyright 2009 GPAllied©
Time to Swallow the Pill
Step 5 – Conduct a Skills and Knowledge Assessment (performance
portion is “hands on” only) Everyone attends training. Highly skilled
personnel become your coaches in the crews.
