How to Develop a Highly

Effective Maintenance Team

Presented by: Ricky Smith, CMRP

July 28, 2010

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A highly effective maintenance team can only
happen when everyone has the same vision.

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 Our MISSION

To Maintain an Asset
– Keep in existing condition
– Keep, preserve, protect

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Two types of failures.

• “A functional failure is the inability of an item (or the

equipment containing it) to meet a specified
performance standard and is usually identified by an
operator”.

• “A potential failure is an identifiable physical

condition which indicates a functional failure is
imminent and is usually identified by a Maintenance
Technician using predictive or quantitative
preventive maintenance”

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The Vision

• To be the best at what we do.

• Seeking improvement everyday.
• Learning is our watchword.

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Potential Failures – Where to Detect them?

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Our Goal

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Step 1: Awareness of a Problem
• Being aware we have a problem
• Identify 4 KPIs to Track and Monitor
 Reliability of Critical Assets - MTBF
 (Mean Time Between Failure)
 PM/PdM Effectiveness - PM vs EM Labor Hours
 Repairs – Rework
 PM/PdM Failure Modes - % of PM/PdM Addressing Specific Failure
Modes of Critical Assets
 Breaks to Maintenance Schedule - # of Breaks to Maintenance
Schedule by Maintenance and Production
• Post and trend KPIs for all to see
• Discuss a KPI with the Team when it is not acting in an
acceptable manner – find the root cause and develop a solution
• Never talk negative or blame any group or person for a KPI
which is unacceptable

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Step 2: Education for all Levels
Define the Vision
- PM/PdM
- Planning / Scheduling, etc
Value of Change
- Management; Lower cost / higher output
- Maintenance Management / less problems, breakdowns
- Maintenance Techs / less stress, more pride
What is a Failure Mode? “How something fails”
– Most work should come from prevention or prediction of specific failure
modes
How do you Measure is your PM Program is Effective?
– “PM Labor Hours vs Emergency Labor Hours”
– Mean Time Between Failures
Execution of work repeatedly and precisely
– Repeatable Operations, PM, CM, Lube Work Procedures
– “Reduce Variation”

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Step 3: Integrate all Training into Work Flow
• All training must be in sequence
• All training involves coaching and mentoring
• Make sure the training effectiveness is measurable

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Step 4: Optimize the Use of Technology
- CMMS/EAM
- Reliability Software
- Ivara
- Meridium
- Predictive Maintenance (not as a predictive tool
but as a Failure Mode Detection Tool)

- Master Plan Tracking

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Step 5: Develop Guiding Principles
Maintenance
• We will eliminate all failures which we deem unacceptable
• We will ensure all paperwork is completed on time and accurately
• We will perform work only once
• We will work with our production partners as a time
• We will stay with production until equipment is operating to
standard

Production/Operations
• Operators will care for the basic needs of their equipment
• Operators will notify maintenance of any abnormality identified
• Operators will stay on station during all breakdowns
• Operators will write work request and notifications for all work

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Step 6: Everyday we will improve
Remember: Excellence must have a standard
and in absence of a standard we have chaos

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• If you want copies of the slides send me a
request
• If you want copies of my Tool Box Training
Sessions send me a request – new copies
every other week
• Questions

rsmith@gpallied.com

“Let’s Make a Difference”

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