All Member Open Forum

 View Only

  • 1.  Reliability and Maintenance Program

    Posted 09-17-2023 07:22 AM

    Hi,

    I just started a new position as reliability and maintenance technician in my organization; an assisted living facility. What is your advice for me on how to develop an effective reliability and maintenance program or roadmap? i will appreciate any links and resources on where to get started. Thank you.



    ------------------------------
    Olumuyiwa Okediran BSc
    Reliability Maintenance Technician
    KENDAL AT HANOVER
    Hanover NH
    ------------------------------


  • 2.  RE: Reliability and Maintenance Program

    Posted 09-17-2023 10:44 AM
    Edited by David Ghavban 09-17-2023 11:15 AM

    To start with, a successful Reliability program necessitates a proactive stance, prioritizing anticipatory actions over reactionary ones. This initiative is propelled by the implementation of consistent and replicable processes to facilitate the maintenance workflow, complemented by well-defined procedural standards to which personnel will receive training and remain accountable.

     
    By following these steps and incorporating industry best practices, you can develop and implement an effective reliability and maintenance program that enhances asset performance, minimizes downtime, and improves overall operational efficiency.

    1. Assessment and Baseline Establishment:

       Conduct a thorough assessment of the current reliability and maintenance practices within the         

       organization. Understand existing challenges, assets, failure modes, and maintenance history.

       Establish a baseline to measure improvements.

     

    2. Stakeholder Engagement and Alignment:

        Engage with key stakeholders, including management, maintenance teams, operators, and     

        other relevant personnel. Ensure alignment of goals, expectations, and the importance of a     

        robust reliability and maintenance program.

     

    3. Risk Assessment and Prioritization:

        Perform a comprehensive risk assessment to identify critical assets, failure modes, and     

        associated risks. Prioritize these based on potential impact on safety, production, and overall     

        business objectives.

     

    4. Data Collection and Analysis:

        Implement a systematic data collection process to gather relevant information about     

        equipment performance, failures, and maintenance activities. Utilize analytical tools to derive     

        insights from the collected data.

     

    5. Root Cause Analysis (RCA):

        Utilize RCA methodologies (e.g., FMEA, FMECA, RCA) to identify root causes of failures and   

        performance issues. Address these root causes to prevent recurrence and improve reliability.

     

    6. Reliability-Centered Maintenance (RCM):

        Apply RCM principles to determine the most effective maintenance strategies for each critical     

        asset. Tailor maintenance activities to the specific needs and characteristics of each asset.

     

    7. Optimize Maintenance Strategies:

        Optimize maintenance strategies by considering factors such as cost-effectiveness, risk     

        mitigation, equipment criticality, and reliability goals. Implement predictive, preventive, and     

        proactive maintenance approaches.

     

    8. Performance Metrics and KPIs:

        Define key performance indicators (KPIs) and metrics to track the effectiveness of the reliability

        and maintenance program. Establish measurable goals and targets for continuous improvement.

     

    9. Training and Skill Development:

         Invest in training and skill development programs for maintenance personnel to enhance their       

         expertise in reliability-focused practices, predictive technologies, and effective maintenance     

         strategies.

      

    10. Technology Integration:

           Leverage advanced technologies such as condition monitoring, predictive analytics, and       

           computerized maintenance management systems (CMMS) to optimize asset performance     

           and maintenance efficiency.

     

    11. Continuous Improvement and Feedback Loop:

          Establish a feedback loop for continuous improvement. Regularly review performance metrics,

          analyze results, gather feedback from stakeholders, and make necessary adjustments to the     

          program to enhance effectiveness.

     

    12. Documentation and Knowledge Management:

          Ensure proper documentation of processes, procedures, maintenance activities, and lessons

          learned.  

          Establish a knowledge management system to capture and share best practices and insights 

          across the organization.

     

    By following these steps and incorporating industry best practices, you can develop and implement an effective reliability and maintenance program that enhances asset performance, minimizes downtime, and improves overall operational efficiency.

    For your reference, How to develop an effective maintenance and reliability program : 



    ------------------------------
    David Ghavban.CMRP
    Moncton NB
    ------------------------------
    -------------------------------------------
    Original Message:
    Sent: 09-17-2023 07:22 AM
    From: Joshua Okediran
    Subject: Reliability and Maintenance Program

    Hi,

    I just started a new position as reliability and maintenance technician in my organization; an assisted living facility. What is your advice for me on how to develop an effective reliability and maintenance program or roadmap? i will appreciate any links and resources on where to get started. Thank you.



    ------------------------------
    Olumuyiwa Okediran BSc
    Reliability Maintenance Technician
    KENDAL AT HANOVER
    Hanover NH
    ------------------------------



  • 3.  RE: Reliability and Maintenance Program

    Posted 09-17-2023 11:12 AM

    These are huge tasks and i believed i have started taken some steps you mentioned above. Thank you David.



    ------------------------------
    Joshua Okediran BSc
    Reliability Maintenance Technician
    KENDAL AT HANOVER
    Hanover NH
    ------------------------------

    Original Message


  • 4.  RE: Reliability and Maintenance Program

    Posted 09-18-2023 05:55 PM

    Hi Joshua,

    For a practical point of view I could give you this few tips:

    1- Know your equipment, know their role in the macro process they are. Understanding what type of equipment, its features, how it operates and what are their standard rates is basic; this would help you to easily potential equipment's failure modes. A step further is understanding what this equipment role in the process? what are its inputs? what are its outputs? Understanding these will not only equip you with its framework but also would enable you to clearly see the potential failure causes and failure consequences. All combined will help you to better make sense of your equipment's MTBF.

    2- Learn which equipment are "fixable" and which are not. If fixable, are they fixable within the organization or externally? and if internally, what are the minimum resources in terms of parts needed to fix it. There is no need to have a very detailed list of parts, what is important here is to determine which equipment have lots of moving parts, which ones require parts from abroad or specialized external service. This will lead you to have a better sense of your equipment's MTTR. 

    I hope it helps.

    Rafael Cardenas, CMRP
    Reliability Engineer
    Stemcell Technologies
    Vancouver, BC



    ------------------------------
    Osmel Cardenas Peñaranda
    Sr.
    STEMCELL Technologies Inc.
    Vancouver BC
    ------------------------------

    Original Message


  • 5.  RE: Reliability and Maintenance Program

    Posted 09-19-2023 08:51 AM

    David is spot on. Nice work!

    I usually start into criticality by getting everyone (reliability engineering, operations, maintenance) to agree on definitions first before going into detail on specific pieces of equipment. Develop a criticality matrix.

    For the Y axis, work with four (or more ? or fewer?) types of work:

    ·       Safety

    ·       Environmental

    ·       Production

    ·       Cost to repair if the equipment breaks down

    To establish criticality, I use the types of organizational responses that maintenance can use to respond to requests for work.

    1.       Stop what you're doing, close what you're working on, and come now (emergent)

    2.       Finish you job, this request is not on your weekly schedule, but it needs to come next (break-in)

    3.       Schedule this job (scheduled)

    That creates your matrix. Next for each cell, define what conditions warrant that response. You'll get everyone agreement that replacing worn safety signs does not warrant a level 1 response.

    Once you have an agreement on a matrix, you have an accepted tool to identify criticality for any piece of equipment in the plant. Each individual piece may require some discussion, but we know everyone agrees on the foundation.



    ------------------------------
    Mike Palm
    Managing Partner
    Convergent Results
    Cockeysville MD
    ------------------------------

    Original Message


  • 6.  RE: Reliability and Maintenance Program

    Posted 09-19-2023 02:43 PM

    David gives a good overview. Unmentioned is planning and scheduling which is integral to all. I consider P&S the hub of all work. I don't know your head count or available systems and processes. Converting one technician to a Planner/Scheduler can double wrench time. Most maintenance crews provide 25% or less wrench time without P&S, some far lower. Expect only incremental improvement at first but a three person crew at 25% is providing about 28 hours of wrench time. Convert one to P&S and in time, the two remaining technicians will provide more than 28 hours in the first few weeks and could increase wrench time to 55%, or 44 hours. Crews of four and more will more than double wrench time at 55%.  



    ------------------------------
    Larry James
    Lockout Larry
    1. Personnel 2. Environment 3. Equipment 4. Revenue
    Reno NV
    ------------------------------

    Original Message