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Integrated Maintenance Management
Pressure to cut cost and global
competition
have forced management to view
maintenance
as the last frontier of plant
efficiency.
Maintenance often has the largest
potential
for operational effectiveness
and management
excellence. The present
day multi divisional
company can no longer afford
a simple "fix
when broken" management
philosophy.
Any attempt to re-engineer and
implement
a maintenance program must
keep in
mind the interdependence of all
divisions
and the organization as
a whole. Most
CMMS implementations fail due
to lack of
planning, training, guidance,
resource allocation
and commitment. One can
extract the
most from a Maintenance Management
system
sooner with assistance
from professionals
in this field. The return on
investment on
a properly implemented Maintenance
Management
program is almost instantaneous!
Predictive Maintenance
This is a means of measuring equipment condition,
to trend the probability of failure. This
significantly alters the original PM program,
and forecasts the need for PM's or repair
based on the condition of the equipment or
asset. Modern technology has produced several
non destructive ways to check on equipment
performance and use their signature patterns
to predict failures.
Vibration analysis, Thermography, Lube analysis,
Ultrasonic testing, Noise,
Gage readings are all some of the examples
of predictive methods utilized
to trend failure regions and organize the
PM program to prevent any
breakdowns from occurring. Depending on the
type of equipment, some of
these tools, will be incorporated into the
regular PM program to be
conducted at regular intervals. Predictive
maintenance tools are not cheap
and the training required to gain the knowledge
to conduct readings and
analyze them requires time and money. However,
the benefits gained from
such an investment will far outweigh the
initial costs very quickly when
these techniques are utilized appropriately
in reducing unnecessary
shutdowns, repairs, and preventive maintenance
tasks, leading to an
optimized maintenance organization.
The long held position regarding failure
is that, with time, parts wear out
and hence they will be prone to more failure.
This is not quite true in the
real world. Let GEMS show you the six distinctive
failure patterns and how
the use of Predictive Maintenance (PDM) can
bridge this gap of uncertainty,
with the trending patterns it provides. GEMS
can assist you with the
development of entire PM program and the
PdM program to achieve optimum
maintenance and reliability.
Proactive Maintenance
Most organizations are run on a crisis mode.
As a result they seldom have
time to run
it proactively. This means that
information
is not analyzed to run their
respective departments.
Some information is produced
but not the
correct type of information needed
to analyze,
correct and re-engineer their
operations.
Information is not standardized
and is kept
by the originator without being
shared by
the entire organization. Duplication
of effort
is common place and the never
ending cycle
of breakdowns and emergencies
are the norm.
Through the efforts of "world
class"
business practices and maintenance
management principles, we can provide the
necessary information and
guidance for you to emerge from crisis mode
to a proactive mode of
operations and the setting up of a proactive
maintenance team.
Relibility Centered maintenance (RCM)
RCM provides the necessary steps for any
organization to look at the equipment
they
are operating from purely their
operational
context. This produces a different
angle
and perspective from the traditional
stance
taken in maintenance which is
keep the equipment
running at all costs based on
design, to
a more pragmatic and specific
maintenance
approach based on its use. This
fine tunes
the work done with the maintenance
management
approach in the previous sections
and further
enhances the types of maintenance
activities
to be conducted.
We will take you through the
entire RCM process
and conduct a thorough FMEA on
your assets
based on criticalities and functionalities.
The end result will be to show
you the types
of maintenance activities needed
as opposed
to what is commonly done. The
result is a
more streamlined and organized
maintenance
department, conducting work with
the optimum
utilization of labor, materials
and equipment.
Corrective Maintenance
Corrective maintenance is not an emergency, unless it truly is an emergency
in the process sense. Repair work is a regular maintenance activity which
can be managed to conduct work in a reliable and timely fashion and at
the same time control costs.
How to organize the maintenance department to satisfy their customers and maintain reliability is a juggling act, but which is not impossible. Production and operational pressures are ever present and most of the time short term remedies and crisis management are popular since these are perceived to be the least expensive and only way to manage their operations. This is the farthest from the truth. Breakdown and crisis management always costs more than planned and preventive maintenance. Nevertheless, no matter what kind of planned program and procedures are in place, there will be equipment and system failures that will take place at random fashion. When that occurs, the maintenance organization and the operational departments must be prepared to handle most of the entire work load or the backlog in a meaningful, prioritized and planned and scheduled manner.
How to do it without increasing risk levels and keeping the customers
happy is the technique that most organization have trouble conceptualizing
and putting into practice. We at GEMS have a tried and tested methodology
that incorporates all the elements of "world class" business
practices that revolves around sound asset maintenance management principles.
We can show you how to make your operations and maintenance departments
become more proactive and move away from the reactive mode of operations.
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