The Maintenance-Excellence Program

By Kris Bagadia and Wayne Vaughn

Most maintenance operations are struggling with a high emergency (unplanned) to planned work-order ratio, an excessive backlog, a lack of sufficient resources, constant work interruptions, not having parts when they are needed, recurring failures, and several similar issues. Stalled productivity, lost compensation, and a less-efficient facility are only a few of the consequences suffered when proper maintenance is botched, ignored, or unplanned.

If you are having these problems, you know that your maintenance operation needs a lot of improvement. By implementing a maintenance-excellence program, you will maximize the performance of your maintenance operation and you will help your operation achieve world-class maintenance. A maintenance-excellence program is a strategic plan of planning and assigning work, managing spare parts, performing preventive and predictive maintenance, utilizing computerized maintenance management system (CMMS)/enterprise asset management (EAM) software, managing data (through data classification, cleansing, enrichment, and gathering), and tracking performance.

This booklet will help you understand the key components of a maintenance-excellence program. It will explain how the program works and its importance in achieving a world-class maintenance operation.

• Language: English
• Publisher: Kris Bagadia
• Release date: Mar 11, 2016
• ISBN: 9781310188442

Kris Bagadia

After eight years of experience as a Plant Engineer and Project Manager for three different manufacturing companies, Mr. Bagadia founded a firm specializing in Maintenance consulting and training. He is the owner and CEO of PEAK Industrial Solutions, LLC. Mr. Bagadia worked as a Maintenance Supervisor for about four years. He has been involved with every aspect of CMMS for over two decades, including, designing, developing, testing, selling and marketing CMMS. He understands maintenance functionality and how a CMMS can accomplish them. Mr. Bagadia authored several books on Computerized Maintenance and has been a contributing author of several handbooks. He published numerous articles in technical and trade journals, has conducted dozens of seminars on Maintenance Management since 1982, and is a frequent speaker for organizations such as Society of Manufacturing Engineers (SME), Institute of Industrial Engineers (IIE), National Manufacturing Week, and a wide variety of universities. He’s an accomplished speaker who makes complex, technical information easy to understand and apply. Publications: •Authored a book “Computerized Maintenance Management System made easy” published by McGraw-Hill •Authored a book entitled “Microcomputer Aided Maintenance Management System” published by Marcel Dekker, Inc. •Authored a book entitled “How to Select and Justify Manufacturing Software” •Authored a chapter “Evolution of Computerized Maintenance Management” in the “Encyclopedia of Microcomputers”, published by Marcel Dekker, Inc. •Authored a chapter in “Materials Handling Handbook” published by John Wiley and Sons. •Authored many technical articles published by various journals. Education: B.S. (M.E.), M.S. (I.E.), PE, CPE Certification/Licenses: Professional Engineer (PE) Certified Plant Engineer (CPE) Website: http://www.peakis.com

Book preview

Preface

Most maintenance operations are struggling with a high emergency (unplanned) to planned work-order ratio, an excessive backlog, a lack of sufficient resources, constant work interruptions, not having parts when they are needed, recurring failures, and several similar issues. Stalled productivity, lost compensation, and a less-efficient facility are only a few of the consequences suffered when proper maintenance is botched, ignored, or unplanned.

If you are having these problems, you know that your maintenance operation needs a lot of improvement. By implementing a maintenance-excellence program, you will maximize the performance of your maintenance operation and you will help your operation achieve world-class maintenance. A maintenance-excellence program is a strategic plan of planning and assigning work, managing spare parts, performing preventive and predictive maintenance, utilizing computerized maintenance management system (CMMS)/enterprise asset management (EAM) software, managing data (through data classification, cleansing, enrichment, and gathering), and tracking performance.

This booklet will help you understand the key components of a maintenance-excellence program. It will explain how the program works and its importance in achieving a world-class maintenance operation.

Maintenance Work Process Flow

Introduction

In most maintenance operations, a work request comes in and is assigned to a technician who completes the request and then moves on to the next job. At best, some preventive maintenance is performed when scheduled. The number of work orders keeps adding to the system every day, never to be seen or reviewed again. This is how maintenance traditionally operates and has been operating for years. In order to achieve maintenance excellence, you must establish a proper maintenance work process flow and planning-and-scheduling model.

Maintenance Work Process Flow

A flawed work process flow causes a large amount of interruptions, leading to an excessive backlog. Typically maintenance organizations use 80–90% of their time on unplanned jobs and 10–20% on planned (preventive included) maintenance. These numbers should be reversed in order to cut down on the amount of emergencies that technicians deal with daily. In order to do this, you will need to implement a proper maintenance work process flow. A proper maintenance work process flow should include eight distinct steps:

Notification

Approval

Planning

Scheduling

Dispatch

Execution

Follow-Up

Reporting Metrics/Key Performance Indicators (KPI)

Many of these steps are missing from most operations. Follow-Up and Reporting Metrics/KPI are rarely