Why is your current PM Program not Effective?

Why Preventive Maintenance Why Preventive Maintenance is not working for Youis not working for You

Presented by: Ricky Smith, CMRPJanuary 2011

Copyright 2010 Copyright 2010 GPGPAlliedAllied©©

January, 2011

Poll – Are current PMs Effective?


Definition of Insanity

Doing the same thing over and over again andexpecting a different resultexpecting a different result


Killer PMsEver heard of them?


Without Proper PM Proactive Work is not achievable


• 70-80 % of equipment failures are Self-Induced

• Putting hydraulic fluid into a reservoir without filtering it

• Welding on equipment without grounding• Welding on equipment without grounding properly

• Aligning couplings without using a laserI l l b i ti l t i t• Improperly lubricating electric motors

• Not using a torque wrench• No Repeatable Procedures

PMsCM / RepairLubricationLubrication


With these issues what do we have?

“High Variation in our Maintenance Process”


Have you ever wondered why reactive i t ?maintenance occurs?

Maintenance – To Maintain, Keep in Existing Condition• Direct work is low (wrench time is less than 30%)• Lack of effective Planning – Planning is not defined• Lack of effective Scheduling – Delays are commonLack of effective Scheduling Delays are common

Failure Modes Driven

Modifying Failure Modes Driven

Strategy Driven Strategy


Reduce Variation


Variation in PM Compliance

10% Rule of PM

2 28 282 2 28

30 Day PM = Due in 3 daysy y


“The significant problems we face cannot be solved with the same level of thinking we were solved with the same level of thinking we were at when we created them.”

- Albert Einstein


Failure Modes Driven Strategy is defined as maintenance strategies (PM/PdM) focused onmaintenance strategies (PM/PdM) focused on

“prevention or identification of specific Failure Modes”Failure Modes .


What is a Failure?“A functional failure is the inability of an item

(or the equipment containing it) to meet a ( g )specified performance standard and is usually identified by an operator”.

• F. Stanley, and Heap, Howard F., Reliability-Centered Maintenance, Department of Defense Report Number A066-579, December 29, 1978


What is a Failure?• “A potential failure is an identifiable physical

condition which indicates a functional failure i i i t d i ll id tifi d bis imminent and is usually identified by a Maintenance Technician using predictive or quantitative preventive maintenance”quantitative preventive maintenance

- F. Stanley, and Heap, Howard F., Reliability-Centered Maintenance, Department of Defense Report Number A066-579, December 29, 1978


PF Curve


I to P – PF Curve is not seen


Failure Patterns

BathtubPattern A = 4%

Initial Break-in periodPattern D = 7%

W O tRandom

Pattern E = 14%

Time Time

Wear OutPattern B = 2%

Time Time

FatiguePattern C = 5% Infant Mortality

Pattern F = 68%

Age Related = 11% Random = 89%


Source: John Moubray, Nowlan & Heap

How to optimize your PM Program?


Step 1: Educate Your Staff


Educate Your Staff, Cont.


Educate Yourself


Step 2: QA/QC PM Execution• Visit the job site• Ask questions

Does the PM look effecti e to them?– Does the PM look effective to them?– Any ideas how we may improve it?– What is your biggest issue with PMs?

• Post PM Effectiveness (PM hrs. vs EM Labor hrs.)


Step 3: Perform a PM EvaluationPM Task ActionRecommendation # of Tasks % of Tasks Man-Hours

RepresentedNon-Value Added %Non Value Added (Delete) 1,640 8.2% 6,661

Reassign to Operator Care 1,380 6.9% 5,605

Reassign to LubeRoute 2,856 14.3% 11,600

Replace with PdM 6 437 32 2% 28 222Replace with PdM 6,437 32.2% 28,222

Re-Engineer 5,200 26.0% 26,221

N M difi tiNo ModificationsRequired 2,487 10.4% 8,987

Totals 20,000 100.0% 87,297


Step 4: Re-write your PMs focused on Failure Modes


NOTE: Re-Write Your PMs so they are Repeatable


Step 5: Begin measuring PM Effectiveness and Efficiency- Effectiveness: Mean Time Between Failure

- Efficiency: PM Compliance using the “10% Rule of PM”


Learn More about Failure Modes• Use ISO 14224 as a help document

(http://www.iso.org/iso/catalogue_detail.htm?csnumber=36979

If you need help let me know• If you need help, let me know• Workshops

(http://www.alliedreliability.com/gpalliedtraining/us_middle_east_asia.asp)

M i t E ll f M i t– Maintenance Excellence for Maintenance Supervisors (talk to me if interested)

– Balancing PM and PdM (Intro to CBM)Balancing PM and PdM (Intro to CBM)– RCM Blitz– Developing Effective Work Procedures– Change Management


“Excellence is a Habit”

- Aristotle, 330 BC


Questions• Send your questions to [email protected]

• Tool Box Training Session are free and you can access them anytimey


Why is your current PM Program not Effective?

Education

Transcript of Why is your current PM Program not Effective?