Preventive Maintenance Training
Preventive Maintenance Training
(OP)
I have been asked to train plant personnel at several other facilities within my organization on maintenance best practices, especially preventive maintenance. These facilities are about 90% reactive and need to change their focus. My thoughts are to bring in a professional trainer who can instill in them the importance of making this change. Has anybody had any experience with training organizations that they could recommend?
Also, if anyone would have any tips or pointers on how to change this culture, I would really like to hear them.
Thanks,
Covey
Also, if anyone would have any tips or pointers on how to change this culture, I would really like to hear them.
Thanks,
Covey





RE: Preventive Maintenance Training
http://www.artllc.com/
Regards,
Dave Gallagher
www.reliabilitydirect.com
RE: Preventive Maintenance Training
I understand your problem, it's very difficult to change the culture where maintenence is a constant ritual of putting out fires. Unfortunately when this is the method of maintenance over a period of years the equipment integrity is terribly compromised. It's almost like rebuilding each machine to a reliable condition and then doing proper PMs
Here are a couple of sites
Training Resource:
http://www.jmssoft.com/courses.html
I visit this one quite often it's very informative
http://www.maintenanceresources.com/referencelibrary/ezine/Aug03v37.htm
Here's another
http://www.reliabilityweb.com/fa/tpm.htm
Good Luck,
ietech
RE: Preventive Maintenance Training
I am in total favor of preventative maintenance and have acted as an instructor in some minerals processing plants, petrochemical plants, mines etc, as an independent consultant. I have no ready made programs, but, the idea is not to jump all over them for the negative side of being 90% reactive, all production units today are mostly reactive with little forethought towards long term goals. We must find out why they are reactive, then teach the technicalities of why they must change to a different culture, but in order to accomplish this we must have the dedicated effort of management.
It will be easy to assess the implications of requirements of changing oil, but the dedication to do it, either has to be understood or planned and dictated.
Tom Coyne, tcinc002@aol.com
RE: Preventive Maintenance Training
Generally, they spend some time on site investigating, use existing manufacturer's manuals, and then prepare generic PM's. I was working with such companies twice, and both times PM's were really general, any experienced maintenance staff person could prepare such (maybe I have no luck with those companies). But there was one good point: technicians were very critical and their remarks became starting point for REAL good PM (details on process you can find at post "PM procedures" here). So, to conclude, you can have use of outside contractors if you don't have people allocated to that task.
Regarding changing the culture, here is one tip: one good way is to separate some mechanics/electricians to a PM group and hold them away from urgent services. This can seem hard, but if you are disciplined it can give visible results even in rather short period. In the beginning even if you cannot give them enough detailed PM for full shift (at least some have to be in place anyhow), give them any routine check for occupation, they only must not be involved in breakdown job. People in this team can be the allways the sme people or everybody could shift from breakdown to PM team - this depends on your evaluation of people, their capabilities, motivation etc. Later, when they become used to fact that there is some job that is not firefighting you can better adjust your organisation procedures.
RE: Preventive Maintenance Training
The best results I've ever achieved in training mechanics came when I selected a team of volunteers to design and deliver the training. We had a training manager on staff that advised the team in the mechanics of training, you could use a consultant for that. There were two big positive results from this approach. The team knew the equipment and environment intimatly. When an issue arose about how to free up mechnanics to be trained the team split up into trainers and substitutes so the work could be covered while the training was done.
Now the bad news. Preventive maintenance is unlikly to make a big change in your breakdown problems in the short term, it takes predictive and proactive programs to do that. It may be difficult to get enough resources free from firefighting to do the PM. Our union contracts allowed us to do PM with the operators. Using the operators in conjunction with a formal management system of their PM work was pretty effective at getting the PM done. It also allowed production management to "schedule" the PM in little chunks every day. Good Luck
RE: Preventive Maintenance Training
The root of the problem is as Iskit mentions, that production and management forces the maintenance department to be reactive by refusing to shut down equipment until it's smoking or passing shrapnel. I feel that any training and education should also include mgmt and production. Once they're "on board" that will open the window for the maint. group to refocus their efforts.
I'm still trying to figure out how I can keep our plant running while helping our other facilities turn their systems around.
Thanks all,
Covey
RE: Preventive Maintenance Training
RE: Preventive Maintenance Training
In regards to training, I firmly believe that although it is helpful for the crews to know PM basics, it really is a concept of management. It would be easier/more efficient to aquire an experinced individual to fill the above focal position, who in turn manages the relationship between production and maintenance. His motivations are based around plant efficiencies.
RE: Preventive Maintenance Training
http://www.datastream.net/products/mp2.asp
The best way to start is to have a PM crew if you have the man power. If not start out slow with certain goals,1 PM each day or shift. Work your way to have Weekly and monthly done on time. Autonomous maintenance my help also.
RE: Preventive Maintenance Training
Regards
RE: Preventive Maintenance Training
One more thing, keep on top of the game to make sure they are not conveniently forgetting to report breakdows to get the free lunch.
RE: Preventive Maintenance Training
It is definitely a management problem, If the production team can over rule the maintenance team, no matter what advanced CMMS program will be choosen, it will fail.
To do maintenance, time must be given to maintenance.
This can be done daily, weekly, monthly, yearly etc.
There must be some higher official above maintenance and production which can make the balance.
Steven van Els
SAvanEls@cq-link.sr
RE: Preventive Maintenance Training
So far we are performing some inspections, however the more senior craftsmen are reluctant to make the change. I don't know just how successful we will be. Involvement of people on the floor is very important if this program is to succeed.
RE: Preventive Maintenance Training
"90% of all failures are caused by maintenance."
This was the attention grabber that should have opened his presentation and we told him so. He didn't take the advise so i guess he still trots it out to a mostly asleep audience.
Anyway, this is just the sort of information to grab attention and upon which to build the idea that all unnecessary maintenance should be avoided. I attended a great pesentation on maintenance at the US NAVY in Washington where someone was talking about predictive maintenance instead of routine maintenance.
Specifically the ability to extend maintenance intervals and achieve a high readiness state among Coastguard helicopters.
It was also a lesson that the manufacturers recomendations are often conservative or targetted on the un-imaginative maintenance teams.
With regard to getting maintenance tasks a priority over production you will need to be able to show that 5minutes for a necessary maintnenace task is better than 1hr for an emergency. If you can't show this, you will never break the mold. You have to show production what's in it for them.
JMW
www.viscoanalyser.com
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RE: Preventive Maintenance Training
Tech, fitters, elect etc need to
1. have a positive attitude cast on them
2. be part of the decission making 'team'
3. be aloud try their own ideas now and then
4. be shown the benifits of PM
5. don't need to be told how to do the job by someone in a suit fresh out of collage. Get an overalls and show them if you can
6. be given the tools and equipment necessary
7. be given the down time, not the teabreak from production
Management and supervisors should actually know how to do the PM or else believe the trained personal. that's what they are trained for.