Loading presentation...

Present Remotely

Send the link below via email or IM

Copy

Present to your audience

Start remote presentation

  • Invited audience members will follow you as you navigate and present
  • People invited to a presentation do not need a Prezi account
  • This link expires 10 minutes after you close the presentation
  • A maximum of 30 users can follow your presentation
  • Learn more about this feature in our knowledge base article

Do you really want to delete this prezi?

Neither you, nor the coeditors you shared it with will be able to recover it again.

DeleteCancel

Make your likes visible on Facebook?

Connect your Facebook account to Prezi and let your likes appear on your timeline.
You can change this under Settings & Account at any time.

No, thanks

Maintenance Excellence

Maintenance Management
by

Jason Wright

on 21 January 2015

Comments (0)

Please log in to add your comment.

Report abuse

Transcript of Maintenance Excellence

1. IDENTIFY
2. PLAN
3. SCHEDULE
4. ASSIGN
5. EXECUTE
6. ANALYZE

1. IDENTIFY
2. PLAN
3. SCHEDULE
4. ASSIGN
5. EXECUTE
6. ANALYZE

IDENTIFY
The process by which maintenance work is identified, justified and prioritized.
IDENTIFY
The process by which maintenance work is identified, justified and prioritized.
Apa aja sih tujuannya
1) Inspeksi (inspection)
2) Kegiatan teknik (engineering)
3) Kegiatan produksi (Production)
4) Kegiatan administrasi (Clerical Work)
5) Pemeliharaan bangunan (housekeeping)

BY: JASON WRIGHT

Identified work should have one or more of the following goals:

Improved safety
Elimination of unnecessary work
Increased reliability and productivity
Correct equipment operation
Continual improvement / eliminate recurring problems
Identified work should have one or more of the following goals:

Improved safety
Elimination of unnecessary work
Increased reliability and productivity
Correct equipment operation
Continual improvement / eliminate recurring problems
Work can be identified from sources such as:
Operator or Technician observations
Safety audits and employee concerns
Maintenance Tactics – Preventive Maintenance (PM), Predictive Maintenance (PdM)
Inspection during PM or PdM tasks
Regulatory requirements
Equipment upgrades
Work can be identified from sources such as:
Operator or Technician observations
Safety audits and employee concerns
Maintenance Tactics – Preventive Maintenance (PM), Predictive Maintenance (PdM)
Inspection during PM or PdM tasks
Regulatory requirements
Equipment upgrades
Planning Considerations:

Highest priorities to Health and Safety items
Each job should be planned only once (Preventive Maintenance work) and then saved for future use
A good maintenance plan will be fully documented and will communicate with Scheduling
Unplanned work costs 3 to 4 times more than planned work.
Planning must be integrated with Materials Management (e.g., Spare Parts) and Maintenance Tactics
Shutdown management
Budgetary considerations/restraints
PLAN The process by which
maintenance work is planned
determines “What needs to be done”,
including:
Amount of work, detailed to task-level, including time requirements
Preparation work by Operations
Required resources (skills, tools, materials)
Required safety procedures
Established or new work procedures
PLAN The process by which
maintenance work is planned
determines “What needs to be done”,
including:
Amount of work, detailed to task-level, including time requirements
Preparation work by Operations
Required resources (skills, tools, materials)
Required safety procedures
Established or new work procedures
SCHEDULE
The process by which maintenance work is scheduled for execution.

Each element of the Maintenance Plan is scheduled in detail. This includes resources, the shutdown and preparation of equipment, and the delivery of tools and materials to the job site.
Requires a backlog of planned work.
About 50% of available manpower should be scheduled for Preventive Maintenance work.
Start with a Daily Schedule, but eventual goal should be a Weekly Schedule.
World’s best maintenance organizations are scheduling work 2 weeks in advance!
SCHEDULE
The process by which maintenance work is scheduled for execution.

Each element of the Maintenance Plan is scheduled in detail. This includes resources, the shutdown and preparation of equipment, and the delivery of tools and materials to the job site.
Requires a backlog of planned work.
About 50% of available manpower should be scheduled for Preventive Maintenance work.
Start with a Daily Schedule, but eventual goal should be a Weekly Schedule.
World’s best maintenance organizations are scheduling work 2 weeks in advance!
ASSIGN
• The process that determines who will execute the scheduled work.
Those assigned to a job must “match” the scheduled work, with consideration of:
Experience
Training and Skills
Availability
Personal limitations (physical, phobias, etc.)
Possible conflicts with other personnel
• Assigned work should be communicated to the technician as far in advance as
possible.
• Once assigned, the completion of the work is the responsibility of the technician.
ASSIGN
• The process that determines who will execute the scheduled work.
Those assigned to a job must “match” the scheduled work, with consideration of:
Experience
Training and Skills
Availability
Personal limitations (physical, phobias, etc.)
Possible conflicts with other personnel
• Assigned work should be communicated to the technician as far in advance as
possible.
• Once assigned, the completion of the work is the responsibility of the technician.
EXECUTE
The process by which planned maintenance work is completed in accordance with the schedule.
This is where the "rubber hits the road"
EXECUTE
The process by which planned maintenance work is completed in accordance with the schedule.
This is where the "rubber hits the road"
EXECUTION CONSIDERATIONS:
Priority scheduling and job plans
Safety requirements
Progress reports/status
Reporting of additional work discovered
Documentation of work performed, cause of failure, parts and tools used, and equipment measurements.
EXECUTION CONSIDERATIONS:
Priority scheduling and job plans
Safety requirements
Progress reports/status
Reporting of additional work discovered
Documentation of work performed, cause of failure, parts and tools used, and equipment measurements.
ANALYZE
The process by which the Maintenance Work Management process is evaluated and adjusted.
ANALYZE
The process by which the Maintenance Work Management process is evaluated and adjusted.
Maintenance work should be evaluated in three key areas:

1. Input Measures
2. Process Measures
3. Output Measures
Maintenance work should be evaluated in three key areas:

1. Input Measures
2. Process Measures
3. Output Measures
ANALYSIS:

1. INPUT MEASURES
-Material costs
-Labour costs

2. PROCESS MEASURES
-Labour distribution
-Work backlog
-Schedule compliance

3. OUTPUT MEASURES
-Equipment availability, reliability, effectiveness
-Measurements to be understood by all
and communicated on a regular basis.
-Key Performance Indicators (KPIs) are the important measures that should be trended
over time and displayed.
-Over time determine which assets had the
highest costs, the most downtime hours,
and most occurrences of outages. Assets
that appear on all three lists need to be
addressed immediately!
Maintenance Tactics:

Corrective Maintenance / Run-to-Failure:
-Maintenance more reactive in nature, sometimes called "repair," is conducted to get equipment working again.

Preventive Maintenance:
-Maintenance more proactive in nature.
-Maintenance of equipment or systems before fault occurs. It can be divided into two subgroups:
(i) Planned Maintenance
example: change filters every three months
(ii) Predictive (condition-based) Maintenance.
example: infrared analysis of a transformer
Performance Measurement

Productivity, Equipment Performance, Cost Performance, Process
Performance, Benchmarking, Balanced Score Cards

Key Performance Indicators (KPI's):
-Meaningful performance measurements as they pertain to facility maintenance operational goals.
-A useful maintenance KPI lets you identify the issues causing your maintenance effects and helps you select the right strategy to either support or correct the actions producing the results.

examples:
(i) % of PM work done = Total PM work/ Total work
(ii) % of Service supply = Outsourced Maint. Costs / Total Maint. Costs
(iii) Asset Cost Control = Maint Costs of Asset / Asset Replace. Cost
FEEDBACK
ASSETS
TEAMS
PROCESS
WORK
MANAGEMENT
MANAGEMENT &
SUPPORT SYSTEMS
BASIC CARE
MATERIALS
MANAGEMENT
PERFORMANCE
MANAGEMENT
STRATEGY
PEOPLE
LEADERSHIP
ESSENTIALS
ENTERPRISE LEVEL
EXCELLENCE
Strategy here means two things:

(1) An overall direction and high-level flexible plan that leads to good choices and supports the organizational objectives.

(2) An overall approach to managing the entire life cycle of specific physical assets within the organization.
-An organization is only as good as its people in effectively accomplishing its goals.
For organizations and employees alike, the only real security is the ability to grow, change, and adapt.
-A.T. Kearney-
Maintenance Work Management
in Six Steps
Maintenance Work Management
in Six Steps
ESSENTIALS

Refers to those core elements of Maintenance Management.
The product of effective handling of maintenance essentials is availability or "uptime".
ESSENTIALS

Refers to those core elements of Maintenance Management.
The product of effective handling of maintenance essentials is availability or "uptime".
PYRAMID of EXCELLENCE in MAINTENANCE MANAGEMENT
PYRAMID of EXCELLENCE in MAINTENANCE MANAGEMENT
Source: Uptime: Strategies for Excellence in Maintenance Management, John D. Campbell
(1) Support Systems:

Data gathering, processing, analysis, and decision-making support used to monitor equipment, establish trends (failure and reliability), forecasting and asset life cycle analysis.

(2) Management Information Systems:

Automated business processes and information flows associated with business transactions within the organization.

The work order is the primary transaction document. They produce reports, schedules, and plans making it possible to see trends and establish performance measures key in decision-making.

Computerized Maintenance Management Systems (CMMS), Enterprise Asset Management (EAM), Enterprise Resource Planning (ERP)
Basic Care is all about doing the things that will
keep the organization running reliably and safely.
Doing the Minimum vs. Exceeding Expectations
"What gets measured, gets done."

-Tom Peters- (In Search of Excellence ,1982)
A key to success in work management is the timely
provision of the materials and parts for maintenance work.
SPECIFY
SOURCE
ORDER
STORE
CONTROL
USE
ANALYZE
Asset:

-Focuses on methods to improve equipment reliability to increase uptime.

-One such methodology is Reliability Centred Maintenance (RCM), Root Cause Failure Analysis (RCFA)
Team:

-Getting the most out of your people, who in turn,
get the most out of your assets.

-One such methodology is Total Productivity Management (TPM)
PROCESS:

-Optimization of the Maintenance Essentials in the organization, i.e. Continuous Improvement
Its A Change Management Problem
Drivers or Enablers
Restraints or Inhibitors
Less work but same pay

Job gets easier

Availability increases

Customer satisfaction

Training
Attrition of staff

No additional pay

Lack of confidence

Change unnecessary,
Poor communication,
Conflict
O
R
G
A
N
I
Z
A
T
I
O
N
CHANGE
ASSET LIFE CYCLE
Dispose
Asset
Strategy

Plan
Evaluate
Design
Build/
Procure

Operate,
Maintain &
Modify

ASSET LIFE CYCLE
Luck is what happens when preparation meets opportunity.
-Seneca, 5 AD-
Luck is what happens when preparation meets opportunity.
-Seneca, 5 AD-
The measure of success is not whether you have a tough problem to deal with, but whether it's the
same problem you had last year.
-John Foster Dulles-
The measure of success is not whether you have a tough problem to deal with, but whether it's the
same problem you had last year.
-John Foster Dulles-
Full transcript