10.3 Maintenance Management Improvements

Preventive Maintenance (PM) Optimization is often thought of as an activity to improve the effectiveness of the maintenance strategy, looking at the activities in the PM routine and matching them with known failure modes. While this is the first step to improving any maintenance strategy, it is just a beginning. In order for an organization to achieve its highest performance, they not only need to do the right maintenance, but they also need to do it efficiently.This is where PM Optimization can unlock the hidden potential. When PM Optimization is combined with known and accepted Lean techniques, the efficiency of maintenance is truly unlocked. When performing PM Optimization, the team should be aware of the 8 types of waste: (1) Defects, (2) Overproduction, (3) Waiting, (4) Not utilizing talent, (5) Transportation, (6) Inventory excess, (7) Motion waste, and (8) Excess processing. Once the team is aware of the waste, there needs to be an unrelenting focus on eliminating the waste and minimizing planned downtime. To eliminate the waste, the team uses various Lean tools, such as SMED, 5s, and Visual Factory. When the 8 types of waste are targeted, the amount of planned downtime goes down, allowing higher levels of asset utilization. Presented at MainTrain 2017

Electrical Maintenance Surveillance Technologies refers to condition based monitoring technology and equipment used every day to inspect electrical distribution assets. These surveillance and inspection systems determine the condition of the individual asset or system being inspected and include but are not limited to: infrared thermography, airborne ultrasound, motor current analysis, partial discharge testing, corona cameras and visual inspections. The implementation challenge is that the inspection and surveillance equipment utilized yield their most valuable results when inspecting electrical distribution equipment that is operating under full load conditions. This is also when they are both most dangerous to maintenance personnel and of the greatest value to the process they are powering. The surveillance equipment implemented normally requires direct access or direct line of sight to the energized components inside the electrical system.  This requires panels to be open which is an extremely dangerous condition. In many cases the posted Arc Fault Currents are too high and legal access is prohibited. This webcast will show how EDSD technologies maintain the energized compartment’s closed and guarded condition ensuring that personnel are not endangered. Participants will learn how the design allows the required test equipment to be used safely at any time, especially when equipment is under full load conditions which is when the inspection yields its greatest value. 

Assessments are used to measure the current state of a program or system against a future or ideal state. A well performed assessment with detailed documented and practical recommendations can have a significant impact on an organisation. Many organisations offer services to perform such measurements; there are likely thousands of companies who solicit and pay for these services every year globally. However for many companies, particularly small to medium sized ones, funding such services can be challenging. With the growing amount of information that is readily available on the internet, best-practices and ‘ideal state’ definitions are no longer the privy of management consultants and industry gurus. This session presents the notion of a ‘self-assessment’ and the case study of one organisation’s decision to develop its own assessment tool and program. The lessons learned and unexpected benefits as a result are also discussed.

​Fully understanding the maintenance and reliability strengths and weaknesses within a facility can be a huge undertaking.  Traditionally, a study to understand reliability is performed by either calculating, tracking, and comparing key performance indicators, or through a qualitative approach, observing compliance with best practices of maintenance and reliability activities to determine perceived strengths and weaknesses. Both approaches have downsides.  In this session, participants will learn about a more effective and repeatable reliability assessment that includes a quantitative assessment using plant CMMS work history to develop trends, key performance indicators, and comparisons that will either validate or invalidate strengths and weaknesses as determined in a qualitative assessment with plant personnel.  See how the ability to reliably gather and assess historical CMMS data will depend on determining a set of requirements or data signatures which can be used to validate strengths and weaknesses.  Additionally, the quantitative cost information can be effectively used to justify projects, programs, and personnel required to improve maintenance and reliability activities. Learn how a reliability assessment can most efficiently and effectively be administered in this way; the use of a qualitative assessment to better focus a quantitative analysis provides the best combination of overall understanding from personnel with the accuracy and reliability of historical data. 

Many factors can influence the success of an Enterprise Asset Management (EAM) /Computerized Maintenance Management System (CMMS) implementation; the most common problems provide the most effective opportunities for improving overall maintenance practices. In this session, learn from Infor Canada how many of its clients have adopted simple and effective strategies that have allowed them to achieve "competence" and "excellence" levels in the Maintenance Maturity Grid. Learn how EAM/CMMS solutions have assisted organizations that use equipment and machinery to produce products, in maintaining the health and life of their equipment. In this session participants will identify the common issues encountered in the implementation of an EAM/CMMS, and learn how to  develop successful strategies not only for a successful implementation, but also continuous improvement maintenance operations, extending beyond maintenance departments. Any EAM/CMMS has the potential to be the most powerful tool in the toolbox of maintenance practitioners. The right strategies will guarantee you succeed in realizing its full potential.

"Uptime - Strategies for Excellence in Maintenance Management" has been a best-seller since 1995. It's 3rd edition includes a number of significant changes from the earlier editions reflecting changes in successful practices, the emerging field of Asset Management and the new imperative that any changes become sustainable. This workshop will provide an overview of the new Uptime "Model of Excellence," introduce the book's new material, explain how it all works and fits within the broader asset management framework.

Today, leaders of organizations are stretched to do more with less. They are asked to cover more areas with fewer resources, with less time and smaller budgets. Given these constraints, how can we continue to drive improvement and achieve success? We must focus tactically to drive improvement and eliminate issues that impact our ability to perform. In this session participants will see how focused improvement efforts can provide significant bottom line impacts and be sustained after the project. Learn how chronic and persistent reliability issues can be solved using a targeted Process Performance OptimizationSM (PPO) approach that integrates best practices in change management, lean and asset management. In order to effectively drive PPO, organizations should focus on this four-step approach along with weaving in an appropriate level of change management to sustain the gains.

Maintenance performance management through KPIs is often not effective because indicators are not visible or understandable at the floor level. Many companies may also not have financial resources to invest in 'high tech' display monitors in the workplace and if they do, content may not be sufficient for specific crew performance measurement and engagement.In this webcast, J.-P will review how KPIs were introduced to maintenance crews and the entire site as part of the Operational Reliability program launched at Cameco's Port Hope conversion facility through simply tools and how concepts of change management were used. See how KPIs could be used at your own organization and what kind of impact they could have.

In 2012, Union Gas – Storage & Transmission Operations (STO) engaged in an improvement initiative called Maintenance Excellence. The motive for engaging in this initiative was the desire to identify and address underlying workforce productivity and reliability issues as well as concerns which remained transparent as STO continued to meet customer demands. This presentation is about Union Gas’ journey from its beginnings in 2012 to its current state today as they continue to pursue Maintenance Excellence. During this session we will discuss Union Gas Storage and Transmission Operations’ journey into Maintenance Excellence. Learn to move from an organization with little documented process and heavy reliance on tribal knowledge to one organized around strong work management processes with the structure to support this. This session will discuss key transformation considerations related to structure, change management and performance measurement.