5 Things You Can Do Now To Calm Down Reactivity

5 Things You Can Do NOW5 Things You Can Do NOWto Calm Down Reactivityto Calm Down Reactivity

Presented by: Ricky Smith, CMRPMarch 2011

Copyright 2011 Copyright 2011 GPGPAlliedAllied

March 2011

It isn’t what you know that will kill you, it h t d ’t k th t illwhat you don’t know that will


“Your system is perfectly designed to give you the results you get”y g

– W. Deming PhD


Reactive Maintenance Attributes• Ineffective or No Planning and Scheduling• PM Compliance has a wide variancePM Compliance has a wide variance• Performing PM on Equipment that continues

to breakdown• Overnight deliveries sit for weeks, months• Everyone works as hard as they can withEveryone works as hard as they can with

little if any movement seen toward proactive• Storeroom is Chaos (people standing in line (p p g

at 7:00am waiting on parts)


Do you want to be Proactive or Reactive?

Not enough hours in the day

Proactive ReactiveWe need to cut back on contractors

Proactive Reactive

Hurry and get those PMs doneHurry and get those PMs done

We need to stop ordering parts


World Class – What does it look like?


World Class Standards• PM Execution – 15%• PM Results – 15%• PdM Execution – 15%• PdM Results – 35%• Total Work “Planned” – 90%• Reactive Work – Less than 2%• Stock outs less than 2%• Stock-outs – less than 2%• Scheduled compliance by day/week – 85 to 90%• Failure Reporting, Analysis, Corrective ActionFailure Reporting, Analysis, Corrective Action

System in place and eliminating failures by changing maintenance strategy and equipment modificationsW k d l d i h ALL C d ID


• Work orders are closed out with ALL Codes ID

Information you must know



Let’s start with the basics – Lessons Learned

• Maintenance – To Maintain• Maintenance Planning – parts staged/kitted, labor hours

estimated coordination identified step-by-step procedure withestimated, coordination identified, step-by-step procedure with specifications

• Maintenance Procedures – Repeatable, Effective ProceduresMean Time Between Failure The most basic measurement of• Mean Time Between Failure – The most basic measurement of equipment reliability

• Preventive Maintenance – To Prevent Failure• Condition Monitoring (aka, Predictive Maintenance)


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 Nowlan and Howard F. Heap, Reliability-Centered Maintenance, Department of Defense Report Number AD-A066-579, December 1978


What Is a Failure?“A potential failure is an identifiable physical condition which indicates a functional failure is i i t d i ll id tifi d bimminent and is usually identified by a Maintenance Technician using predictive or quantitative preventive maintenance ”quantitative preventive maintenance.- F. Stanley Nowlan and Howard F. Heap, Reliability-Centered Maintenance, Department of Defense Report Number AD-A066-579, December 1978


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%


Source: John Moubray, Nowlan & Heap

PF Curve



5 Things You Can Do NOW to Calm Down Reactivity5 Things You Can Do NOW to Calm Down Reactivity


Variation is Your Enemy - Causes• No Repeatable/Effective Procedures• Lack of Discipline in maintenance executionLack of Discipline in maintenance execution• The wrong maintenance approach to reliability• Production not operating the equipment toProduction not operating the equipment to

standard• PM Compliance is Too WidePM Compliance is Too Wide• Doing Too Much PM


Number 1 – Awareness of a Problem (baby steps)

• Track Self/Human Induced Failures• Set up a chart listing these failures and causes /Set up a chart listing these failures and causes /

No names or blaming• Establish an atmosphere of calmness but p

focused• Use Tool Box Training Sessionsg• Apply the “D” Word (Discipline)

“YOU CANNOT CHANGE AN ENVIRONMENT OVERNIGHT”


Tool Box Talk – Single Point Learning

Copyright 2011 Copyright 2011 [email protected]

70 to 80% of Failures are Self / Human Induced

• Lubricating bearing improperly• Adding oil to a hydraulic reservoir with a bucket

and f nneland funnel• Over-tensioning V-Belts• Welding on Equipment• Use of Half Links on Chain Drives• Not having a procedure for rebuild of gearbox• Not using a torque wrenchNot using a torque wrench• PM Execution Variance is High


Number 1 - Identify Human Induced Failures• Identify and Post all Human Induced Failures• No judgment, solutions identified with yourNo judgment, solutions identified with your

crew at end of each week, 30 minute meeting


Variation Continues - A Deadly Killer


Number 2 – Reduce Variation in PM Compliance“C iti l A t O l ”“Critical Assets Only”

10% Rule of PM

2 28 282 2 28

10% Rule of PM

30 Day PM = Due in 3 daysy y


Number 3 – Break out crew • 20% of crew to emergencies• 20% to PMs• 20% to results from PM• 20% to Lubrication• 20% to Priority 2 – 3 work (backup for emergency

crew)

EM 2 PM 2EM -2 PM -2

PMR -2Pri. 2 -2

Lube -2

Pri. 2 2


Continuous Improvement – Failure Elimination


a

Number 4 – Failure Identification/Elimination


Failure Elimination• Measure Mean Time Between Failure (MTBF)

(MTBF Users Guide)

• Post in the shopp• Talk to your maintenance techs• Ask for suggestions

• Measure EM vs PM Labor Hours


Number 5 - Perform a PM Evaluation

PM Task ActionRecommendation # of Tasks % of Tasks Man-Hours

RepresentedNon-Value Added (Delete) 1,640 8.2% 6,661

Reassign to Operator Care 1,380 6.9% 5,605Care , ,

Reassign to LubeRoute 2,856 14.3% 11,600

Replace with PdM 6,437 32.2% 28,222

Re-Engineer 5,200 26.0% 26,221

No ModificationsRequired 2,487 10.4% 8,987

Totals 20,000 100.0% 87,297


Example PM Task – No value (Delete)1. Check pump2. Check motor2. Check motor3. Check conduit


Labor Hours to Use for Proactive Work

PM Task ActionRecommendation # of Tasks % of Tasks Man-Hours

RepresentedNon-Value Added (Delete) 1,640 8.2% 6,661

Reassign to Operator Care 1,380 6.9% 5,605Care , ,

Reassign to LubeRoute 2,856 14.3% 11,6006 more Maintenance TechsReplace with PdM 6,437 32.2% 28,222

Re-Engineer 5,200 26.0% 26,221ONo ModificationsRequired 2,487 10.4% 8,987

Totals 20,000 100.0% 87,297

Iii

12,266


Questions“It is all about the Failure Modes”


Let’s Review• Number 1 - Identify Human Induced Failures• Number 2 - Reduce Variation in PM ComplianceNumber 2 Reduce Variation in PM Compliance• Number 3 - Break out crew • Number 4 - Failure EliminationNumber 4 Failure Elimination• Number 5 – Perform a PM Evaluation


Education - Options to Increase Effectiveness

1. Maintenance Tips – send me an email2. Up Coming Workshops in Charleston, SC Introduction to Condition Monitoring Planning and Scheduling Reliability Engineering Fundamentals Developing Effective Work Procedures Routine Equipment Care Routine Equipment Care RCM Blitz Root Cause AnalysisRoot Cause Analysis Leading Sustainable Change

3. Private Workshops are available


Questions?Questions?

[email protected]


Technology

5 Things You Can Do Now To Calm Down Reactivity