Brian -
Good morning.
In the SMRP Body of Knowledge look at 1.4 Stocked Maintenance Repair, and Op Materials (MRO) Inventory as % of RAV. Pay special attention to the caution at the end.
Here is my personal experience from two vastly different food manufacturing facilities. Total annual maintenance spend to RAV and MRO to RAV
In a large liquid batch process facility (pumps, pipes, valves, and vessels) heavily automated. We were on the low side of this around 1.5%. Stocked inventory as around 2-3% of RAV
At a more traditional food mfr facility (raw material grind/blend, form, cook, freeze, bag) with individual cell automation we were a little higher and closer to the middle of the best practices estimate, around 4%. I'm not sure what our inventory to RAV was, but I'm assuming it was in the 1%-1.5% range. Improvement projects were often centered around development of equipment standards towards installed equipment consolidation. We also had a fantastic planner and maintenance superintendent, and incredibly supportive maintenance/operations/plant mgmt.
Both facilities were well run, efficient, productive, and safe. Probably not world class, but very solid facilities.
As you start chipping away towards making a plan more productive you can approach problems from multiple directions.
- Efficiency, getting more sellable product out of the uptime you have.
- Reliability, keeping equipment running - don't let it break.
- Maintainability, make it easier and quicker to fix when it does break (documentation, procedures, MRO mgmt, training)
Rhetorical questions to consider:
What is the ultimate objective of your "reliability" program?
- You aren't going to fix everything overnight. Find a couple areas to address, get others involved, and start making daily progress.
Is your plant currently at capacity?
How confident are you in the data behind your RAV calculation?
How confident are you in the data feeding into your "maintenance cost"
What is your maintenance cost per unit of product?
Library Additions:
John Ross - 2 Books, *LinkedIn Follow, MRO Processes and Metrics Specialist
Ron Moore - What Tool When, Common Sense Common Practice
Doc Palmer - Maintenance Planning & Scheduling
John Reeve - Failure Modes to Failure Codes *Great LinkedIn follow as well
Hope this helps!
Feel free to give me a call if you would like a sounding board.
--
Eric J. Foreman
SMRP NE/IA Education & Communication Director
Cedar Rapids, Iowa
Mobile - (319) 777-2555