5 Things You Can Do Now To Calm Down Reactivity

5 Things You Can Do NOW to Calm Down Reactivity
Presented by: Ricky Smith, CMRP March 2011

Copyright 2011 GPAllied
It isnt what you know that will kill you, it what h t you dont d t know k that th t will ill
Your system is perfectly designed to give you the results y you g get
W. Deming PhD
Reactive Maintenance Attributes

Ineffective or No Planning and Scheduling PM Compliance has a wide variance Performing PM on Equipment that continues to breakdown Overnight deliveries sit for weeks, months Everyone works as hard as they can with little if any movement seen toward proactive Storeroom is Chaos (p (people p standing g in line at 7:00am waiting on parts)
Do you want to be Proactive or Reactive?

Not enough hours in the day We need to cut back on contractors
Proactive
Reactive
Hurry and get those PMs done
We need to stop ordering parts
World Class What does it look like?
World Class Standards

PM Execution 15% PM Results 15% PdM Execution 15% PdM Results 35% Total Work Planned 90% Reactive Work Less than 2% Stock outs less than 2% Stock-outs Scheduled compliance by day/week 85 to 90% Failure Reporting, Analysis, Corrective Action System in place and eliminating failures by changing maintenance strategy and equipment modifications Work W k orders d are closed l d out with i h ALL Codes C d ID
Information you must know
Lets start with the basics Lessons Learned

Maintenance To Maintain Maintenance Planning parts staged/kitted, labor hours estimated coordination identified, estimated, identified step-by-step procedure with specifications Maintenance Procedures Repeatable, Effective Procedures Mean Time Between Failure The most basic measurement of equipment reliability Preventive Maintenance To Prevent Failure Condition Monitoring (aka, Predictive Maintenance)
What Is a Failure?
A functional failure is the inability of an item (or the equipment containing ( g it) ) to meet a specified performance standard and is usually identified by an operator.
- F. Stanley Nowlan and Howard F. Heap, Reliability-Centered Maintenance, Department of Defense Report Number AD-A066-579, December 1978
What Is a Failure?
A potential failure is an identifiable physical condition which indicates a functional failure is i imminent i t and d is i usually ll identified id tifi d by b a Maintenance Technician using predictive or quantitative preventive maintenance maintenance.
- F. Stanley Nowlan and Howard F. Heap, Reliability-Centered Maintenance, Department of Defense Report Number AD-A066-579, December 1978
Failure Patterns
Bathtub
Pattern A = 4%
Initial Break-in period

Pattern D = 7%
W Out Wear O t
Pattern B = 2%
Time Time
Pattern E = 14%
Random
Fatigue
Pattern C = 5%
Infant Mortality
Pattern F = 68%
Age Related = 11%
Random = 89%
Source: John Moubray, Nowlan & Heap Copyright 2011 GPAllied
PF Curve
5 Things You Can Do NOW to Calm Down Reactivity
Variation is Your Enemy - Causes

No Repeatable/Effective Procedures Lack of Discipline in maintenance execution The wrong maintenance approach to reliability Production not operating the equipment to standard PM Compliance is Too Wide Doing Too Much PM
Number 1 Awareness of a Problem (baby steps) Track Self/Human Induced Failures Set up a chart listing these failures and causes / No names or blaming Establish an atmosphere p of calmness but focused g Sessions Use Tool Box Training Apply the D Word (Discipline)
YOU CANNOT CHANGE AN ENVIRONMENT OVERNIGHT
Tool Box Talk Single Point Learning
rsmith@gpallied.com
70 to 80% of Failures are Self / Human Induced

Lubricating bearing improperly Adding oil to a hydraulic reservoir with a bucket and funnel f nnel Over-tensioning V-Belts Welding on Equipment Use of Half Links on Chain Drives Not having a procedure for rebuild of gearbox Not using a torque wrench PM Execution Variance is High
Number 1 - Identify Human Induced Failures

Identify and Post all Human Induced Failures No judgment, solutions identified with your crew at end of each week, 30 minute meeting
Variation Continues - A Deadly Killer
Number 2 Reduce Variation in PM Compliance

C iti l Assets Critical A t Only O l
10% Rule of PM
2 28 2 28 2 28
30 Day y PM = Due in 3 days y
Number 3 Break out crew

20% of crew to emergencies 20% to PMs 20% to results from PM 20% to Lubrication 20% to Priority 2 3 work (backup for emergency crew)
EM -2 2 PM -2 2
Pri. 2 -2 2
PMR -2
Lube -2
Continuous Improvement Failure Elimination
a
Number 4 Failure Identification/Elimination
Failure Elimination
Measure Mean Time Between Failure (MTBF)
(MTBF Users Guide)
Post in the shop p Talk to your maintenance techs Ask for suggestions
Measure EM vs PM Labor Hours
Number 5 - Perform a PM Evaluation

PM Task Action Recommendation Non-Value Added (Delete) Reassign to Operator Care Reassign to Lube Route Replace with PdM Re-Engineer No Modifications Required Totals # of Tasks 1,640 1,380 , 2,856 6,437 5,200 2,487 20,000 % of Tasks 8.2% 6.9% 14.3% 32.2% 26.0% 10.4% 100.0% Man-Hours Represented 6,661 5,605 , 11,600 28,222 26,221 8,987 87,297
Example PM Task No value (Delete)

1. Check pump 2. Check motor 3. Check conduit
Labor Hours to Use for Proactive Work

PM Task Action Recommendation Non-Value Added (Delete) Reassign to Operator Care Reassign to Lube Route Replace with PdM Re-Engineer No Modifications Required Totals # of Tasks 1,640 1,380 , % of Tasks 8.2% 6.9% Man-Hours Represented 6,661 5,605 ,
2,856 14.3% 11,600 6 more Maintenance Techs 6,437 5,200 2,487 32.2% 26.0% 10.4% 28,222 26,221 8,987
20,000
I i i
100.0%
12,266 87,297
Questions
It is all about the Failure Modes
Lets Review
Number 1 - Identify Human Induced Failures Number 2 - Reduce Variation in PM Compliance Number 3 - Break out crew Number 4 - Failure Elimination Number 5 Perform a PM Evaluation
Education - Options to Increase Effectiveness

1. Maintenance Tips send me an email 2. Up Coming Workshops in Charleston, SC Introduction to Condition Monitoring Planning and Scheduling Reliability Engineering Fundamentals Developing Effective Work Procedures Routine Equipment Care RCM Blitz Root Cause Analysis Leading Sustainable Change 3. Private Workshops are available
Questions?
rsmith@gpallied.com

5 Things You Can Do Now To Calm Down Reactivity

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5 Things You Can Do Now To Calm Down Reactivity

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5 Things You Can Do NOW to Calm Down Reactivity

Presented by: Ricky Smith, CMRP March 2011

Copyright 2011 GPAllied

Copyright 2011 GPAllied

Reactive Maintenance Attributes

Copyright 2011 GPAllied

Do you want to be Proactive or Reactive?

We need to stop ordering parts

Copyright 2011 GPAllied

World Class What does it look like?

Copyright 2011 GPAllied

World Class Standards

Information you must know

Copyright 2011 GPAllied

Copyright 2011 GPAllied

Lets start with the basics Lessons Learned

Copyright 2011 GPAllied

Copyright 2011 GPAllied

Copyright 2011 GPAllied

Initial Break-in period

Age Related = 11%

Copyright 2011 GPAllied

Copyright 2011 GPAllied