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Change is required to improve in Maintenance, RCM is a positive change…

Thursday, July 23rd, 2009

The reason to change any process including manufacturing or maintenance is desire for improvement; to be better than your competition.

 

In today’s world, the main driving force for change is quality (of product, service, and work) and cost reduction. To improve quality or save money you need to introduce some sort of change; you need to modify, transform or completely move away from your current practices. We all know that in order to succeed in any change, the entire organization (from top to bottom) needs to understand the necessity for change and be dedicated and supportive in adopting it. The same applies within the Maintenance organization.

 

RCM is a positive change for the maintenance process –and inspection routes are one of the most important aspects to implement from RCM. Why?

 

If you are not observing equipment condition continuously –either with some sort of continuous monitoring system (Condition Based Maintenance) or with inspection routes,  then your maintenance department will never move away from being reactive. It is virtually impossible to continuously monitor an entire system, or where possible, it can be very expensive. Many companies are now using a combination of both or using only inspection routes with Maintenance Management responsible for Inspector training and motivation, as well as route optimization. The reason for this is that the majority of RCM action plans call for human sense inspections that can only be achieved by inspections and routes.

 

Recording data during an inspection can be a painful process especially if you’re printing out routes and entering data manually into CMMS. But with use of handheld computers (which Ivara offers), the entire process is automated. An Inspector enters his inspection data into the handheld. He/she is immediately warned of any out of normal readings based on pre-set thresholds. When the route is done, all data is transferred wirelessly into Ivara EXP, providing Maintenance with a centralized view of all condition data from all sources. With this centralized view of essentially real-time data, Maintenance is empowered to make informed decisions, ensuring the right work send to the CMMS for completion.

 

With diligence to this proactive process, inspection routes catch equipment failures in early stages which results in saving money, time and effort. The whole game is about equipment uptime; elimination of unwanted long downtimes and costly repairs.

July 23rd, 2009      Condition Based Maintenance - Implementation Success - Process & Practices - RCM   Leave a Comment »

Implementing RCM–Tips for training trades on executing routes when they have no prior reliability experience or training

Tuesday, June 30th, 2009

You’ve done RCM, now what? A key part of implementing RCM is getting the condition monitoring routes required to maintain the equipment into action. Here are a few practical tips for RCM Implementors to ensure tradespeople that have no prior reliability experience or training will conduct the condition inspection routes essential to the success of the new program:

  • At first, arrange with the supervisors or managers who are familiar with RCM and have them explain to the Inspectors/Operators the changes in the program and what are you planning to do on the floor.
  • Be very friendly – take the time to get to know people, exchange pleasantries, it makes a difference –and be good listener. Always finish by thanking –say “Thanks for your time”. Show some appreciation for this essential work.
  • You will likely have to repeat yourself several times, so be patient. Soon enough, you will see results. Share those results with the Inspectors / Operators.
  • Never show your disappointment or dissatisfaction. If you show any type of negative feelings you may destroy all chances of getting anything done.
  • If the Inspectors/Operators get discouraged, spend the time to encourage them. Tell them “Yeah, I know it’s difficult but you’ll pick it up. It took me a while too, but don’t worry. And –I’ll keep coming to show you until you can do it yourself”.
  • When they say “We don’t check that equipment very much” remind them why we are doing RCM, they will tend to easily forget because they have been doing the same thing for the past 20-30 years. Be firm yet polite.
  • Make sure they have the proper training and reference materials on how to use the handheld devices used to conduct the inspections.
  • When necessary, make sure you inform and utilize area supervisors/managers if you are having a hard time.
  • Be patient. Certain people will pick up quickly on how to use the handhelds; some people will take a long time. You may have to walk through the routes with Inspectors/Operators until they are comfortable.
  • Use wording that the operators/inspectors will be familiar with (there is a possibility they have never heard terms like “route”; use “checksheet” for example).
  • For route validation try to get in touch (as per area manager/supervisor recommendation) with the best Inspectors/Operators).
  • Show willingness to prepare/structure routes as much as possible the way they like it.
  • If necessary, use paper routes at the beginning for max. 4 weeks and show them how to enter data into the handhelds. Then involve them in entering data onto handheld and little by little transfer entire process onto the handhelds.

June 30th, 2009      Condition Based Maintenance - Process & Practices   2 Comments »