10 Vital steps in achieving world-class manufacturing maintenance practices

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Gather Data and Calculate Downtime Costs

Assemble information on machine downtime, meantime between machine failures, expenditures on parts, technology usage, technician response time and the percentage of on-time deliveries

This will enable you to calculate the average cost of one hour of downtime

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Determine the dollar value of maintenance

With an average per-hour downtime cost estimate, you can project how much money maintenance improvements would save

You can determine how much value an increase in availability will add

Even a 5% increase, translates into a huge improvement

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Analyze operational variables

When determining projected productivity increases from improved machine availability, it’s also important to factor in the savings your maintenance operation

For example, take a look at how a better plan to handle critical spares, introduction of a work order system and faster technician response time could impact availability

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Invest in a technology solution

A technology solution can improve the handling of variables across the board

A computerized maintenance monitoring system (CMMS) provides work order information and improves technician response time, lowering the mean time to repair and reducing downtime

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Start scheduling preventive maintenance

With a CMMS that enables processing of work orders, you can easily monitor all manufacturing assets in operation, track critical parts and spares

So you’re ready to schedule preventive maintenance and generate checklists to manage maintenance tasks

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Deploy a scheduler planning function

As you transition from reactive maintenance to a more proactive stance, schedule technicians’ time for preventive maintenance and ensure that the right parts are available when needed

A scheduler planning function is a critical tool for reducing downtime and maximizing the value of preventive maintenance

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Introduce predictive tools

Preventive maintenance reduces downtime, and a predictive maintenance checklist can improve machine availability

The type of predictive tools you’ll need will depend on the equipment your team maintains. Electrical equipment can be hampered by overheating, so a thermography tool can prevent trouble

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Total Productive Maintenance (TPM)

After predictive maintenance, the next step is to get operators involved in TPM

To leverage operators’ familiarity with manufacturing assets, find simple solutions that enlist operators in maintenance, such as keeping assets clean and freshly painted to aid in visual inspection or installing sight gauges that enable operators to monitor fluid levels

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A Reliability Centered Maintenance (RCM) strategy

With a clearer view of machine capabilities and status, you no longer have to take equipment offline for preventive maintenance

You can maximize value with a cost-benefit analysis of maintenance vs. Productivity needs.

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Bring in third-party technicians

Achieving world-class maintenance involves a cultural transformation and it may be necessary to bring in third-party resources to establish metrics and define processes

If you are looking outside your company to achieve the cultural shift you require, make sure to get references to ensure the right fit with your organization

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Excerpts taken from original article in Plant Engineering

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