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  • 1.  How do you handle missed PdM/CBM inspections?

    Posted 07-20-2022 07:10 PM
    How do you handle missed PdM/CBM inspections ... for example, when a thermographer runs an electrical infrared route, and 20% of the equipment isn't energized because it powers inline spares or other equipment that isn't currently operating?  If I missed 20 of 100 machines, Production might only be able to give me 2-3 machines per week for the next few weeks, depending on when they can swap to spares or when they'll run equipment that they only use 1 week per month for specialty grades in the product wheel.  How do you document what you inspected and what you missed, and then how do you manage getting back to inspect the equipment you missed on the primary inspection?

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    Timothy Holmes
    Principal Consultant, Reliability & Maintenance Systems
    Dupont
    Dickson TN
    timothy.r.holmes@dupont.com
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  • 2.  RE: How do you handle missed PdM/CBM inspections?

    Posted 07-21-2022 08:51 AM
    This is a good question that I often wonder if I'm doing correctly.  I have a vibration route with the same issue.  I try to have each machine collected at least once per quarter.  I keep track with a spreadsheet.  I make several attempts to arrange collection with operations.  Usually, I'm able to collect about 80 - 90% of machines by the end of the quarter.  I've yet to get to 100%.  At the end of the day, I'm not too concerned about equipment that runs so infrequently that I can't collect it.  Equipment like this may benefit more from visual inspection or other offline testing.

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    Emanuel Washington
    Maintenance Reliability Engineer
    Oak Ridge National Laboratories
    Oak Ridge TN
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  • 3.  RE: How do you handle missed PdM/CBM inspections?

    Posted 07-22-2022 07:15 AM
    It is a practical issue, but as it is high-priority work we have to somehow cover 100% of the equipment. We need to get operation on board on this.
    What we did was we lined up CBM routine with the equipment change-over routine in CMMS and the scheduler set this on the weekly plan. 





  • 4.  RE: How do you handle missed PdM/CBM inspections?

    Posted 07-22-2022 10:55 AM
    Tim Holmes, after describing his situation, asks, "How do you document what you inspected and what you missed, and then how do you manage getting back to inspect the equipment you missed on the primary inspection?"

    To Tim I would say do not take his answer from a discussion site. Instead, take time to carefully understand the production operation and his own maintenance (support) to the prod op. Thence, carefully flowchart the entire flow of cases, decisions and actions as they are and in turn flowchart solution flow of cases, decisions and actions. A discussion site such as this one can only give him some thoughts but never a valid solution to his unique case. 





  • 5.  RE: How do you handle missed PdM/CBM inspections?

    Posted 07-22-2022 11:53 AM

    Richard,

     

    I appreciate your reply, and you are 100% correct.  "The devil is in the details" and no two sites, even production units, are exactly the same.  What works in one plant (even in one unit at a plant vs. another unit at the same plant) may not work as well at another plant that is organized differently, has people and work processes at different maturity levels, etc.

     

    You need to have a game plan that matches the knowledge, skills, and abilities of your team.   Coach Calipari at Kentucky doesn't use the same tactics with freshman-laden teams that Coach Self at Kansas uses with teams having more upperclassmen as starters.

     

    As you recommend, we have charted the Maintenance Work Management Process (MWMP) for decades.  We have corporate standard practices, as well as (for the reasons above) some local adaptation.

     

    I'm just wanting to make sure that we have considered any good ideas put forth in the Discussion Group, methods that others have found work for them, as closing the loop on the more complex MWMP issues can be challenging.

     

    Thanks again.

    Tim

     

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  • 6.  RE: How do you handle missed PdM/CBM inspections?

    Posted 07-22-2022 12:55 PM
    The logistics of support (as what maintenance functioning is supposed to be) are to be integrated to the mission and productive demands on the plant's production system as it fulfills the firm's competitive strategies. Rather than the "devil is in the details" the thrust of our solutions should be the design of the logistics of maintenance functioning integrated to production operation.

    Unfortunately, most of our discussion across maintenance and reliability is about our methods and desires rather than how to integrate our collective methods in the context of logistics to realize the plant's mission. Doing so is actually a field of systems engineering known as integrated logistics support (ILS). 

    I'm reminded of the commercial about getting a shingles shot. We can exercise and eat right and meditate but "Shingles doesn't care." Production management doesn't care about our best practices unless they are in the context of ILS.





  • 7.  RE: How do you handle missed PdM/CBM inspections?

    Posted 07-22-2022 12:32 PM
    TBH, I typically see there is no good system to manage that.  I usually see it is just picked up on the next round.  I am not sure any organization is good enough to manage all the rounds and a second layer of missed stuff for all kinds of reasons.  Many times we are not even staffed to make the initial rounds as drawn up.

    Second thought is if the equipment isn't running then the criticality might not be as critical either so missing a cycle may not be as detrimental as it feels.  This might be true for something that is not running since it is a spare.  

    Also dig a little deeper and understand the failure mode you are trying to prevent or manage and what the P-F interval is.  That can tell you a lot about your risk for missing a route datapoint.

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    Randy Riddell, CMRP, PSAP, CLS
    Reliability Manager
    Essity
    Cherokee AL
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  • 8.  RE: How do you handle missed PdM/CBM inspections?

    Posted 07-25-2022 07:02 AM
    Edited by CELESTINE ESO 07-25-2022 10:09 AM
    Perfect! In my over a decade of managing PMRs and CBM, I have come to understand that there is no perfect way to managing missed equipment in a particular PMR schedule as these schedules will repeat themselves in the near future. However, we have always considered the production/safety criticality and failure history of the equipment to determine if we have to wait for the next schedule to attend to them, or make a case with Operations to make the equipment available for PMR/monitoring.

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    CELESTINE ESO MSc
    Snr Plant Engineer
    Bonny Island
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  • 9.  RE: How do you handle missed PdM/CBM inspections?

    Posted 07-26-2022 08:44 AM

    Everyone has provided great insights, and I would like to acknowledge that there is no perfect system. That said, please take into consideration when forecasting the work a few aspects that have served me well. 

    Weigh the scheduled activity, its importance against the equipment, and its operational criticality. 
    If the activity is not executed, what can be the operational, production, and equipment impact?
    What has been the rate of occurrence?
    What is the potential downtime?
    Finally, how many times has this activity been deferred?
    Evaluate, set realistic expectations, and take a pragmatic approach to your maintenance activities.
    Ensure that your daily inspection includes some objectivity that can capture any significant variance to support the need for the PM, PdM, or CbM activity. 

    I hope this is of help. 

    Regards,
    Ralph



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    Rafael Sanchez
    CEO & Sr. Reliability Consultant
    R&M CMMS Consulting, LLC
    Austin TX
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