World Class Maintenance Attributes

Attributes of a World Class Maintenance Operation World Class Maintenance Operations require all maintenance and reliability processes to be optimized, repeatable, and effective.

World Class Maintenance requires:

1. Preventive Maintenance to be effective.

2. Maintenance Rework to be minimal.

3. PM/PdM is focused on identification or prevention of specific “Failure Modes”

4. PM/PdM effectiveness measured using Mean Time Between Failure (MTBF)

by:

> Site

> Area

> Asset

> Equipment/Component

5. Maintenance Cost is measured by Asset Type

6. Maintenance Planning and Scheduling is effective by:

> Ensuring Planning is effective.

> Ensuring Scheduling is effective by scheduling work by day by hour

> Planning and Scheduling is effective by mitigating "Human Error."

> Planning and Scheduling in addition reduces Maintenance Cost, see the Benchmarks below:

6. Planning Process is effective and measured by:

> 15% Work is PM

> 15% Work from PM results

> 15% Work is PdM

> 35% Work from PdM Results

> 90% Planned Work

Definition: Planned Work: Work that has gone through a formal planning process to identify labor, materials, tools, and safety requirements. This information is assembled into a job plan package and communicated to craft workers prior to the start of the work. Source: SMRP Best Practices

Repeatable procedures with specifications and standards mitigates human error by:

• Step by Step Instructions
• Estimated labor hours by craft
• Estimated time for work order execution
• Parts Required
• Potential parts identified and reserved.

Results should be: Emergency/Urgent Labor Hours account for 2% of total labor hours.

4. Maintenance Scheduling is effective Maintenance Scheduling requires maintenance, operations, engineers, agree on the Maintenance Schedule, by work order, at least one week

> Scheduling Compliance at least 85%, measured by labor hours

> Scheduled Compliance is given to work completed on the day scheduled if it has been scheduled at least one week out.

5. Work Execution is effective and is Measured by percent of Rework

"Rework is corrective work done on previously maintained equipment that has prematurely failed due to maintenance, operations or material problems. The typical causes of rework are maintenance, operational or material quality issues.

Rework Source: SMRP Best Practices

This World Class Maintenance process requires the following:

• Job to be planned and scheduled
• Repeatable procedures
• Parts kitted/staged
• Wrench time above 55%
• Time estimated +/‐ 10%
• Work Order Close Out is effective.
• Over 100% of work orders are closed out to 100% of standard

Standard: Required Data Fields identified by Reliability Engineering and Maintenance Management

• Data fields are identified based on Metrics, Key Performance Indicators (KPI), and failure reporting required to manage a World Class Operation

This is the Continuous Improvement Process for Maintenance and Reliability, where decisions are made based on data in order to change a maintenance strategy, operating procedures, or Reports are generated and acted upon based on specific criteria defined by Maintenance, Operations, and Reliability Management in order to mitigate or eliminate equipment failures.

At a minimum, the following reports are required:

• MTBF down to the component or part level
• Mean Time Between Repairs (MTBR)
• Top 6 Dominant Failure Patterns for site, area, system

Ensure that the corrective maintenance strategy and approach is applied

Verify that outages are needed and, if so, which equipment has a failure pattern that is age related and not random.

Dominant Failure Threads – which component/part fails the most as a result of the same cause across a site, line, asset.

Example: Part – Bearings (47 failures)

Cause: Lack of Lubrication (92% of the time) = Dominant Failure Thread

Conclusion:

The journey to World Class begins with a plan which has been defined. The rewards are great and amazing.

If you would like a copy of this article, go to my website at: www.worldclassmaintenance.org