I’ve seen organizations that operate in a reactive environment, attempt to “jump-start” a proactive maintenance mode by adding manufacturer recommended Preventive Maintenance (PM) in bulk, and/or by adding a Predictive Maintenance (PdM) program. However, if fundamentals aren’t in place, PM, PdM and other programs will likely have limited success, and today’s neglected proactive work becomes tomorrow’s emergency work.
Before you begin adopting new strategies, you must firmly establish and practice the Fundamentals of Maintenance:
- Detect and identify problems early
- Enter Work Orders (WOs) when problems are detected
- Plan and schedule WOs in advance
- Properly execute work and capture history
- Analyze historical data for Continuous Process Improvements (CPI)
If these fundamentals are in place, a good starting point is to analyze equipment history and find the “bad actors” (by cost, number of failures, etc.). By looking at the known failure modes and rates, you are able to define and eliminate the root cause for the failures, and establish the best method of early detection (PM, PdM, operator rounds, etc.). Once you have determined a frequency that allows early detection, you can then begin properly planning, scheduling and executing proactive work. Establishing the Fundamentals of Maintenance and aligning them with a PM and/or PdM program will improve equipment uptime and reduce maintenance costs.
Jeromy Risner, CMRP