First, even in developed countries, industrial companies and providers of ERPs (enterprise management systems) are technologically very backward in this specialty.

Second, those very little companies or experts who developed differentiated technology keep it safe guarded as a trade secret.

This exposure results in considerable accumulation of knowledge and expertise, and a unique set of observations and conclusions which certainly could not fail to be shared with the concerned community. [Read more…]

by James Kovacevic 2 Comments

The 5 Levels of Maintenance Scheduling

airline schedule board — Photo by Qfamily

Making Maintenance Scheduling Simple

Coordinating all of the maintenance activities within a site can be overwhelming. A schedule is supposed to help reduce the sense of being overwhelmed. But why is it that when trying to pull together a schedule for the next shift, day or week, it always seems to be a mad dash?

Often times the maintenance scheduling process is not well defined or thought out, and this leads to being overwhelmed. It also projects an image to our operational partners that we do not have our house in order. This image may or may not play a role in having our Maintenance windows moved or cancelled, further our scheduling issues. [Read more…]

by Mike Sondalini Leave a Comment

Differential Pressure Transmitters

The differential pressure transmitter (PT) is used to detect a head of pressure.

The sensing element is connected to the process by pipework and flexes in proportion to the pressure. The resulting distortion produces an electric signal that is amplified and converted to a value on a read-out.

Keywords: pressure sensor, strain gauge, tank level, process pressure, pressure difference. [Read more…]

by Doug Plucknette 1 Comment

Safety Is a Lifestyle

Something to think about in a day and age when most companies post their mission, vision, and goals on the company web page.

Do we really stand behind these statements and demonstrate the behaviors that clearly show we are willing to do what it takes to create a safe workplace?

If you have ever questioned this, consider two questions I ask RCM Teams as we analyze failure modes that impact health, safety, and environment: [Read more…]

by James Reyes-Picknell Leave a Comment

Linking RCM Facilitation with Effective Maintenance Program Implementation

Most of us would agree that there is a new global economy being forged right now in the manufacturing sector.

Inevitably, this translates to a renewed focus on transferring more business value to the customer. Central to this will be linking RCM (Reliability Centered Maintenance) facilitation with effective maintenance program implementations.

In short, the difference between what we, as RCM Facilitators, have been doing in the past and what we will be doing from now on is: a strong emphasis on what tactics are required in order to achieve the failure management strategies an RCM Team defines.

That is, we will conduct the decisions phase of the analysis somewhat differently. (i.e. The 3rd pass through when walking-the-dog in an RCM analysis) [Read more…]

by James Kovacevic 1 Comment

The Black Hole of Maintenance

black hole image — Photo by Steve Jurvetson

Where Maintenance Requests Go But Never Appear to Escape From- the Backlog.

This is exactly what some operations staff think of when we tell them to submit a work request.

It means that they do not think that the work will be completed, or it will after it no longer matters to them.

What if you called the cable company and reported an issue? You would expect prompt service, and would expect that you would not have to chase them down to do the work correct? Maintenance is a service organization that enables the successful operation of the business.

The business shouldn’t have to chase us down or wonder if we will repair the equipment. [Read more…]

by Mike Sondalini 1 Comment

Job Descriptions Tell Tradesmen What to Do

Abstract

The first words a maintainer will read when they pick up a work order is the job description. The job description must tell him enough information about the work so he can understand what to do.

Keywords: CMMS, computerized maintenance management system, planning, breakdown repair, corrective. [Read more…]

by Doug Plucknette Leave a Comment

Engaging Your Workforce

Engagement

A word that has several meanings- most think of an upcoming wedding, a young couple excited about the idea of getting married, starting a home and a family together and all the exciting things that come with being in love.

But this isn’t the kind of engagement I want to talk about today. [Read more…]

by James Reyes-Picknell Leave a Comment

Searching for Quick Fixes Now Leads to Problems Down the Road

I want it now and I want it cheap! Oh – and I don’t want to do any work for it.

When it comes to information, entertainment, finding your way around and communications these days, we more or less literally have it all at our fingertips and available to us just about anywhere.

We can even order and pay for coffee to pick up on our way from the commuter train to the office – no lineups for delays. We can book hotels, airlines and rental cars at the touch of our fingers with apps that show us the cheapest options.

We live in a world where instant gratification is a reality in many aspects of our private lives.

Consumer electronics has transformed a great deal of business – basically, anything where there is a service or goods that a consumer might buy on their own, we can get it easily and immediately.

We’ve grown used to instant gratification in much [Read more…]

by James Kovacevic 4 Comments

What is Maintenance Planning?

Measuring tape on construction drawing — Photo by Markus Spike

Understanding what is included in maintenance planning will enable your program to be successful.

Maintenance planning = doing things right. Identifying and addressing any possible issues ahead of time enables our craft to complete work quickly and correctly.

Maintenance planning identifies the what, why and the how. These three items allow the planner to identify most potential issues and provide the information, and materials to avoid them. [Read more…]

by Mike Sondalini Leave a Comment

Agitator Shafts Thrust Bearing

Vertical tank agitator bearings are required to take both radial and thrust loads.

To protect the gearbox it is common practice to install intermediate bearings on the shaft. If these bearings are exposed to the process vapors then special care is needed to protect them from contamination and ensure adequate lubrication.

Keywords: thrust bearing, bearing stool, roller bearing. [Read more…]

by Doug Plucknette Leave a Comment

The Top 5 Signs of a Reliable Plant

Having visited hundreds of manufacturing plants in the last 15 years, someone recently asked me if there were any traits the most reliable plants all had in common.

I have listed below the top 5 signs of a reliable plant.

Sign 1 – The plant is clean!

The plants that are top performers are clean all of the time, clutter is unacceptable, and the tasks required to keep the plant clean are routine business. [Read more…]

by James Kovacevic Leave a Comment

Planning for Profitability

Man working at desk — Photo from Seattle Municipal Archives

How Maintenance Planning & Scheduling Can Improve Your Profitability

What if you could improve your maintenance department to the point where you increase the efficiency and the amount of work completed of your department by 80%? Would this be something that interests you?

A properly setup and managed Maintenance Planning & Scheduling Program can enable that type of success and enable your operation to plan for profitability.

This type of increase in efficiency may seem farfetched, but it can be achieved. The typical maintenance department operates between an efficiency of 30-35%, with best in class departments operating at 55% or better. What separates these operations? Planning & Scheduling! [Read more…]

by James Reyes-Picknell Leave a Comment

Cost Control or Value Generation?

If you can’t sell all you can produce, then reducing costs is often the only way to improve margins, but that simplistic accounting perspective is not always the case.

Cost control is often thought to be key to attaining profitability but it the case of maintenance it can get you into trouble.

Cost control can have a big opportunity cost if you don’t take advantage of the opportunities you have. [Read more…]

by Mike Sondalini Leave a Comment

Making Walkways and Platforms

Here are the things to watch out for when you need to fabricate platforms and walkways.

Stairs, walkways, platforms, and ladders are required to be made to the Australian Standard AS 1657-1992. This standard specifies the design requirements and the materials of construction to be used.

Keywords: deflection, allowable load, live load, guard rails, connections, treads. [Read more…]