October 12, 2006
Start Up Tip
Twelve reliability deliverables are required to be in place prior to starting up a factory.
Over the next several weeks each one will be defined. These are tasks which must be completed to build ownership at the shop floor to ensure the equipment is maintained as installed. In order to sustain the condition of the equipment and maintain its ability to perform, operating and maintenance systems must be in place. First reliability deliverable is “obtain and enter complete equipment data into the CMMS.” The best time to specify data requirement is prior to purchasing the equipment. Engineering specifications and Request for Proposals (RFP) should clearly identify the information which the vendor must provide. If for some reason the information cannot be obtained from the vendor (for example: used or salvaged equipment),use the work order system and plan for a mechanic to gather the information when the equipment arrives at the site. The minimum amount of information should be nameplate data, drive component data, bearing data, lubrication requirements, power requirement, specific equipment details and manuals. This equipment data is the starting point for developing maintenance plans for a piece of equipment.
Tip provided by Kevin Lewton
MET DEMAND
http://www.metdemand.com
October 12, 2006
Asset Management Tip
Asset Management is increasingly being considered by industrial organisations around the world.
PAS 55:
PAS 55 was developed by the Institute of Asset Management in the UK and the British Standards Institute for the optimal management of physical assets that are key in achieving business objectives and effective service delivery. It was originally designed for infrastructure assets and follows experience gained over 25 to 30 years of deregulation in the UK.
PAS 55 offers a structure of processes and activities for management to follow so that they can determine where the gaps are to enable a cycle of continual improvement; its foundation is therefore about processes and management.
EAM:
Is a comprehensive Computerized Maintenance Management System, which enables
• The control of maintenance work, planning, documentation control, record keeping and information systems etc.,
• and additional features of project and contractor management etc., if required.
Overview:
Both the above programmes are relatively new and are largely different. PAS 55 focuses mainly on organisational commitment and culture in managing its processes to meet its objectives in the short, medium to long term, whereas, EAM administers the work control process.
The perfect solution would be a combination and alignment of the two, to enable the organisation to identify the processes that need improved management and to administer the operation with some of the latest CMMS solutions.
Tip provided by Jack Huggett
The Woodhouse Partnership Ltd
http://www.twpl.com
October 12, 2006
Join the Commtest Revolution
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October 12, 2006
Preventive Maintenance (PM) Tip
This tip concerns one possible way to design your PM
tasks and frequencies.
PM is like advertising. You know that half of it is wasted. The great challenge is knowing which half.
There is a pointer within your grasp that will only point at PM tasks that will make a difference. This pointer is the parts that you use.
Process: Review the parts that you use and make a listing of all the parts that failed because of breakdown. Sort these so that the most frequent parts failures lead the list. Divide those failures into three categories (this will look
somewhat familiar if you are a RCM devotee).
1. Parts failures where there is a safety or environmental exposure.
2. Parts failures where large costs were incurred in parts, labor, scrap or downtime.
3. Most frequent failures not in the above categories.
Starting with category 1 look at the parts and the failures. Is there a task that would have eliminated the failure?
After category 1 is complete do the same analysis on category 2 and 3. Always include the cost of the task in the
review and choose tasks that give you a big bang for your buck!
This type of approach can be very effective to tighten up a PM program.
Tip: Add a series of tasks to your PM schedule on your computer system that initiate the review of the 5 most used breakdown parts. Have the analysis be performed by a knowledgeable trades person and give it a labor standard or 4 or more hours.
Good Luck
Joel Levitt
Author - Time Management for Maintenance Professionals
Time Management for Maintenance Professionals
Human Error Tip
Work stress is:
a. The leading cause for medication errors in the US (49%)
b. A significant contributor to aircraft crashes (65%)
c. A cause involving 23% of significant nuclear power plant events
Tip provided by Bob Latino
Reliability Center Inc.
http://www.reliability.com
October 05, 2006
Lean Maintenance Tip
In a large study done in Canada they estimated where lean maintenance projects could save money or increase output. There are opportunities all around us. Here is what they found:
Percentage of possible savings of maintenance budget dollars
39% Re-engineering of equipment and maintenance improvements to equipment
26% PM improvement and correct application of PM
27% More extensive application of predictive maintenance
7% Improvements in the storeroom
Work in each of these areas can result in significant reductions in cost or improvements in operation. Of course there are hundreds of projects that these percentages represent.
Areas to focus on for a lean project that will result in cost cutting or improvements in production:
1. Labor (production operator, maintenance mechanic and contractor)
2. Maintenance parts, materials
3. Raw materials (reduce scrap, quality problems)
4. Energy, fuel, other utilities including water
5. Machine time (reduce machine time to complete job)
6. Capital (extend life of asset, cheaper asset, less equipment reduces effective capital costs)
7. Management effort (reduce headaches, non-standard conditions requiring management inputs)
8. Overhead
Tip provided by Joel Levitt
Springfield Maintenance
http://www.maintrainer.com
New On CD: Lean Maintenance in a Nutshell Audio CD by Joel Levitt
October 05, 2006
Coolant Tip
What is the pH of your coolant telling you?
Coolant pH can provide valuable clues to potential cooling system problems. pH is a measure of a coolant’s acidity or alkalinity and indicates the intensity of the fluid’s acid- or base-forming ability. The pH for conventional coolants is typically 8.5 – 11.0 (OAT and HOAT are typically 8.0 – 9.5). If pH drops rapidly - below 8.5 for conventional and below 7.5 for OAT and HOAT - but remains above 7.0, and ageing coolant is not a factor, air could be leaking into the cooling system. A drop below 7.0 could indicate combustion gas blow-by.
October 05, 2006
Make Maintenance Work at IMC-2006
Learn what you can do to make maintenance more effective at your facility in just 4 days at IMC-2006 - The 21st International Maintenance Conference, December 5-8, 2006 in Daytona Beach Florida.
People who have attended our past conference know that there is a HUGE difference at Reliabilityweb.com events. Over 90% report that they took back strategies, techniques and tools to directly improve maintenance. We understand how valuable your time is and we work hard to make the time you spend at IMC-2006 the most productive possible.
We are sure that IMC-2006 will be worth the time you invest in attending. If for any reason you are dissatisfied with your experience at this conference, we will refund 100% of your paid registration fee.
Attendance is limited to ensure quality. Watch for full program details in the next issue of Uptime Magazine or at the conference web site.
It is important that you register quickly to avoid disappointment. Reliabilityweb.com events generally SELL OUT two - three weeks prior to the actual event.
Request an IMC-2006 Brochure and you will automatically be registered to win one of 100 IMC-2006 Proceeding CDs to be given away in a drawing on December 11!
Please call toll free (888) 575 1245 to learn more about IMC-2006, early bird registration discounts, Daytona Hilton hotel discounts for just $83 per night (limited time and supply only)!
October 05, 2006
Ultrasound Tip
Winters coming, are your windows and doors sealed? Try using ultrasound to be sure.
Ever stand by a door or window in your home or office and feel cold air rushing through along the window or door seal? Open up your ultrasound kit and you may find that the little box that you have never used inside the kit is in fact useful. Most ultrasound manufacturers today make a tone generator. A tone generator is typically a box like instrument supplied by the manufacturer when you purchased your ultrasonic instrument. This instrument when turned-on emits a high-frequency that floods an area. The sound is capable of penetrating small openings (holes or seams). Place this outside to locate the leak internally or exit path. Place the generator inside to locate the entrance from the outside and stay warm all winter.
Tip provided by Jim Hall
Ultra-Sound Technologies
October 05, 2006
Planning and Scheduling Best Practices Survey
Reliabilityweb.com has agreed to assist some hard working authors who are writing a new book on planning and scheduling. May we request 15 minutes of your time to provide some input to guide this project?
You can take this survey anonymously or your can leave your contact details if you would like an advanced copy of the survey summary report as soon as it is completed. We appreciate your assistance.
October 05, 2006
Best Practices in Maintenance & Reliability
Next Workshop Date – October 17-18, 2006
Detroit, MI
In this exciting and challenging workshop Ricky Smith explores Best Practices of Maintenance and Reliability, defining industry best practices and the metrics used to measure their effectiveness. World-class maintenance and reliability standards have been developed by “best-of-the-best” companies in the world of reliability and in this workshop you will learn how to apply these practices to your plant the moment you return to work.
Valuable Take Aways
• Ivara’s Maintenance and Reliability Practices Assessment Template – Based on a comprehensive benchmarking exercise conducted across global industries and refined over several years, this template documents 4 stages of progress supported by 120 criteria requirements.
• Ivara’s Financial Assessment Template – Use this template to assess the financial impact of improved reliability in your organization.
If you operating in a reactive maintenance environment or want to take your maintenance department to a new level of performance then this is the workshop for you. Don’t miss this event!
If you have specific questions email Ricky Smith at or call him at 843-906-8686.
For more information on Reliability workshops, and to register click here.
