How To Develop A World Class Maintenance Team

Copyright 2010 GPAllied©

Presented by: Ricky Smith, CMRP

July 28, 2010

How to Develop a Highly

Effective Maintenance Team


A highly effective maintenance team can only

happen when everyone has the same vision.


To Maintain an Asset

– Keep in existing condition

– Keep, preserve, protect

Our MISSION


Two types of failures.

• “A functional failure is the inability of an item (or the

equipment containing it) to meet a specified

performance standard and is usually identified by an

operator”.

• “A potential failure is an identifiable physical

condition which indicates a functional failure is

imminent and is usually identified by a Maintenance

Technician using predictive or quantitative

preventive maintenance”


The Vision

• To be the best at what we do.

• Seeking improvement everyday.

• Learning is our watchword.


Potential Failures – Where to Detect them?


Our Goal


Step 1: Awareness of a Problem

• Being aware we have a problem

• Identify 4 KPIs to Track and Monitor

Reliability of Critical Assets - MTBF

(Mean Time Between Failure)

PM/PdM Effectiveness - PM vs EM Labor Hours

Repairs – Rework

PM/PdM Failure Modes - % of PM/PdM Addressing Specific Failure

Modes of Critical Assets

Breaks to Maintenance Schedule - # of Breaks to Maintenance

Schedule by Maintenance and Production

• Post and trend KPIs for all to see

• Discuss a KPI with the Team when it is not acting in an

acceptable manner – find the root cause and develop a solution

• Never talk negative or blame any group or person for a KPI

which is unacceptable


Step 2: Education for all Levels

Define the Vision

- PM/PdM

- Planning / Scheduling, etc

Value of Change

- Management; Lower cost / higher output

- Maintenance Management / less problems, breakdowns

- Maintenance Techs / less stress, more pride

What is a Failure Mode? “How something fails”

– Most work should come from prevention or prediction of specific failure

modes

How do you Measure is your PM Program is Effective?

– “PM Labor Hours vs Emergency Labor Hours”

– Mean Time Between Failures

Execution of work repeatedly and precisely

– Repeatable Operations, PM, CM, Lube Work Procedures

– “Reduce Variation”


Step 3: Integrate all Training into Work Flow

• All training must be in sequence

• All training involves coaching and mentoring

• Make sure the training effectiveness is measurable


Step 4: Optimize the Use of Technology

- CMMS/EAM

- Reliability Software

- Ivara

- Meridium

- Predictive Maintenance (not as a predictive tool

but as a Failure Mode Detection Tool)

- Master Plan Tracking


Step 5: Develop Guiding Principles

Maintenance

• We will eliminate all failures which we deem unacceptable

• We will ensure all paperwork is completed on time and accurately

• We will perform work only once

• We will work with our production partners as a time

• We will stay with production until equipment is operating to

standard

Production/Operations

• Operators will care for the basic needs of their equipment

• Operators will notify maintenance of any abnormality identified

• Operators will stay on station during all breakdowns

• Operators will write work request and notifications for all work


Step 6: Everyday we will improve

Remember: Excellence must have a standard

and in absence of a standard we have chaos


• If you want copies of the slides send me a

request

• If you want copies of my Tool Box Training

Sessions send me a request – new copies

every other week

• Questions

[email protected]

“Let’s Make a Difference”

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How To Develop A World Class Maintenance Team

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