Asset criticality and strategy: Perform criticality ranking (HSE, production, quality, cost) and select a blended strategy - run-to-failure where justified, time-based for age-related modes, and condition-based/predictive for random failures. Tie targets to lifecycle and business goals.
Failure modes and task design: Conduct RCM/FMEA to identify dominant failure modes; design precise tasks with clear intervals, trigger points, acceptance criteria, and shutdown logic. Keep strategies "living" via evidence updates.
Work management discipline: Build detailed job plans (tools, parts, permits, torque values), plan/schedule weekly with frozen windows, track schedule compliance, and control backlog health (age, priority mix, volume).
Precision maintenance foundations: Enforce base/shaft alignment (laser), soft-foot correction, proper grout and baseplate stiffness, piping strain checks, field balancing, correct fits/clearances, seal and bearing handling, and torque-controlled assembly.
Lubrication excellence: Specify lubricants by duty and environment, set quantities/intervals, implement contamination control (desiccant breathers, filtration), manage storage/dispensing, and use ultrasound/particle counts to optimize intervals.
Installation and commissioning: Apply cleanliness standards, verify foundations and pipe strain, capture baseline vibration, noise, thermography, and electrical signatures; perform acceptance testing with documented tolerances.
Condition monitoring program: Define routes and frequencies by criticality; deploy vibration (overall, spectra, enveloping), oil analysis (wear metals, viscosity, PQ, water), thermography, and ultrasonics. Rationalize alarms and integrate to CMMS to auto-generate work.
Data and analytics integration: Maintain clean master data (tags, taxonomy, BOMs), link sensors to assets, store baselines, trend KPIs, and apply simple analytics before ML; ensure change control for thresholds to avoid alarm floods.
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Olalekan Ogunbanjo
Automation Engineer
AstraZeneca
Bollington
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