Maintenance Culture

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MAINTENANCE CULTURE

@ MAMA CASS RESTAURANTS LIMITED

By Osagie Alfred


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Definition of Terms

Maintenance is the sum total of actions taken to prevent adevice, component or equipment from failing as well as therepair of normal equipment degradation experienced with theoperation of the device to keep it in proper working order.

Culture in this context is a particular set of attitudes thatcharacterizes a group of people


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What is Maintenance?


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Maintenance Perception

Maintenance is costly

OPERATIONS + MAINTENANCE = PRODUCTION

Therefore, facilities Maintenance Department should be given necessaryattention given to Operations (Cafeteria, Jaydens etc).


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Maintenance Perception (contd)

Until recently, maintenance has not always been considered a main-stream function. It has always been seen as a negligible sub-system ofproduction and probably, a necessary and an unplanned overhead.

Maintenances primary responsibility is equipment reliability. In the

present climate of increased globalisation and the obligation toreduce production costs, the assets of a company capital, buildingsand machinery, - are much more critical than ever before.

Consequently, the importance of managing assets efficiently andeffectively has become very germane to the bottom-line of

organisations. business reality.


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Maintenance Strategy Options

Planned: Preventive, Predictive, Reliability Centered etc

Unplanned: Corrective Maintenance


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Maintenance StrategyComparison

MaintenanceStrategy Advantages Disadvantages

Resources/Technology Required

Breakdown/Corrective

No prior workrequired

Disruption of production,injury or death

May need labor/partsat odd hours

Preventive Work can bescheduled

Labor cost, may replacehealthy components

Need to obtainlabor/parts for repairs

Predictive Impending failurescan be detected &work scheduled

Labor costs, costs fordetection equipment andservices

Vibration, IR analysisequipment orpurchased services


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Composition

PreventiveMaintenance + MCRL FacilitiesPreservationCorrectiveMaintenance

For Critical For non-critical


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Autonomous Maintenance.

Safety Concerns

Safety is one of the most important restrictions.

Autonomous tasks apply only for simple repair operations.

Repair or maintenance should never be performed if the knowledge required to fixthe machine is high.

PM orders carried out by the production workers. Known as user maintenance orders.

They should be simple and graphically represented. Many inspection tasks should becarried out every day.

Significant amount of notices that could be easily handled by the production worker.It takes more time to fill out the request order than to fix the problem

Autonomous maintenance includes these small tasks and three daily preventivemeasures.

Cleaning, lubricating and checking.


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Autonomous Maintenance.

Safety Concerns

Safety is one of the most important restrictions.

Autonomous tasks apply only for simple repair operations.

Repair or maintenance should never be performed if the knowledge required to fixthe machine is high.

It can be very challenging to convince production workers about the importance ofmaintenance tasks. They do not consider their responsibility.


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Autonomous maintenance

Autonomous maintenance implementation process has a specific

methodology. These include

Initial cleaning1Countermeasures to Sources of Contamination2

Cleaning and Lubricating Standards3Overall inspections4Autonomous Maintenance Standards5Process Quality Assurance6

Autonomous Supervision7


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Human-Facilities Similarities

They both have life and life-span

They need regular check-ups

They need replacement of parts.


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Elements of Equipment Reliability

Appropriate specification and design practices

Professional purchasing practices

Appropriate storage facilities

Precise installation methods

Well defined and consistent start-up and commissioning procedure

Consistent operating practices

Proactive maintenance processes.

Reliability, just like safety, is EVERYONES responsibility


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Elements of Equipment Reliability


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Buildings

original design,

size and facilities

Elements of Building Reliability

Finishes and

equipment

specified for

installation

Affect

Property Operation & Maintenance (POM) related costs

Quality of

construction used

in building


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The bath-tub curve


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Basic Maintenance Actions

Never assume knowledge of any equipment/machine

Switch off all electrical appliances when not in use (e.g. Laptop)

Do a routine check on all your work equipment before settling into the days work.

Report all potential hazard and fault.

Be humble and willing to learn, every equipment, component etc is unique in its

own way. Ask questions when in doubt, never assume you know what to do.

Report faults objectively and not be an alarmist. Dont cry wolf where there is none.

Do routine cleaning and check on all components.

Develop a maintenance culture and see yourself as a stakeholder in the

maintenance of the equipments under your custody.

A mal-functioning system is a hazardous system.


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Situation Report

Equipment are used to run-down

No due diligence check before equipment are purchased.

Existing equipment have been inadequately maintained.

Lack of a Comprehensive Facilities Management software.

Lack of Condition Assessment tools e.g.

Lack of up-to-date Asset Register


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Establishing Maintenance Culture1. An effective Job Order system

2. Replacement Policy

3. Employees accept responsibility for

Observe, Check, Adjust, Clean and Notify

4. Well-trained personnel

5. Adequate resources

6. Proper application of the three maintenance strategies

7. Continuous research and improvement.

8. Due diligence check before equipment are purchased.

9. Conduct annual comprehensive facilities audit.

10. Purchase of a Comprehensive Facilities Management software.

11. Continuously run an up-to-date Asset Register. equipment/systemreliability


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Documents

Maintenance Culture