4 steps to success for maintenance supervisors

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Copyright 2010 GPAllied © Presented by: Ricky Smith, CMRP July 8, 2010 4 Steps to Success for Maintenance Supervisors

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Maintenance Supervisors are the people who make the largest impact on reliability in most organizations and thus I created this One Hour WebEx to provide ideas which will allow them to far exceed management’s expectations. Subjects to be covered in this one hour session: • Why Preventive Maintenance Does not work and what to do about it • How to make life easier in managing a Proactive Maintenance Team (and the road map to get to this point) • What is Maintenance Excellence and what does it mean to a Maintenance Supervisor • The 4 Steps to Success in Maintenance Supervision I will be using my past experience as a maintenance supervisor and “lessons learned” while working with hundreds of maintenance supervisors for the past 15 years to transfer my knowledge to these great maintenance leaders. I sincerely want to see maintenance supervisor become the best they can be. Maintenance Supervisors have the most difficult job in any organization and yet they can achieve a higher degree of satisfaction with their job by using a few simple tips.

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Page 1: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Presented by: Ricky Smith, CMRP

July 8, 2010

4 Steps to Success

for

Maintenance Supervisors

Page 2: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

“Maintenance Supervisors are the people who

make the largest impact on reliability in most

organizations and if trained and empowered

effectively they will far exceed management’s

expectations”

Ricky Smith, former Maintenance Supervisor

Page 3: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

What is Maintenance?

• To Maintain an Asset

– Keep in existing condition

– Keep, preserve, protect

Page 4: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Potential Failures – Where to Detect them?

Page 5: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Our Goal

Page 6: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Failure Modes Driven Strategy

What is a Failure Mode?

– “How something fails”

Most work should come from prevention or

prediction of specific failure modes

Example: Part – Bearing

Failure Mode – Wear

Cause – Lack of Lubrication

Prevention – Effective Lubrication

Page 7: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Step Number 1 – PM Evaluation

Evaluate a sampling of your PMs

1. Review each PM with a few of your maintenance

staff

2. Sort the PMsStack 1 – PM adds no value

Stack 2 – PM adds value but give to ops

Stack 3 – PdM will address this PM earlier and more effectively

Stack 4 – PM needs to be re-written

Stack 5 – PM is good

3. Identify the number of labor hours identified in each

stack – how many labor hours did you save?

Page 8: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Example of a PM Evaluation

PM Task Action

Recommendation# of Tasks % of Tasks

Man-Hours

Represented

Non-Value Added

(Delete)1,640 8.2% 6,661

Reassign to Operator

Care1,380 6.9% 5,605

Reassign to Lube

Route2,856 14.3% 11,600

Replace with PdM 6,437 32.2% 28,222

Re-Engineer 5,200 26.0% 26,221

No Modifications

Required2,487 10.4% 8,987

Totals 20,000 100.0% 87,297

Page 9: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Failure Mode Driven StrategyWork Flow of Planning and Scheduling

Proactive Work

PM/PdM Planning SchedulingWork

ExecutionW.O. Close

OutFRACAS

Proactive Work

Page 10: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Step Number 2 – Work Order Information

Rules which are not optional

1. Work Orders for all work

2. Work Order Codes must be accurate

3. How do you make this happenWork Flow of Planning and Scheduling Proactive Work

PM/PdM Planning SchedulingWork

ExecutionW.O. Close

OutFRACAS

Proactive Work

Page 11: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Work Order Close Out

If you need a training guide send me an email

at [email protected]

Page 12: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Work Order Close Out – Who Cares?

Page 13: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Do you and your crew know where you are?

Page 14: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Common Failure Threads

• Develop a Process which delivers the Report

you want.

– Dominant Failure Pattern

Page 15: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Mean Time Between Failure

Page 16: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Culture: Defining Roles and Responsibilities

TasksMaintenance

Supervisors

Maintenance

Planner

Maintenance

Technician

Maintenance

Manager

Reliability

Engineer

PdM

Technician

Inputting Failure

Data -

CMMS/EAM

A I R C C

Work Order

Close Out R C R A R R

Validating

Failure Data and

Codes

C I C A R C

QA of Failure

Data InputI C A R C

Analyze Failure

ReportsR I C R A/R R

Making

Maintenance

Strategy

Adjustments

I I I A R C

Responsibility “the Doer”

Accountable “the Buck stops here

Consulted “in the Loop”

Informed “kept in the picture”

Page 17: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Step Number 3 – Change your Culture

• Culture Change is not easy

• How do you change your culture?

• One step at a time

Page 18: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

“The significant problems we face cannot be

solved with the same level of thinking we were

at when we created them.”

- Albert Einstein

Page 19: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Re-invent Yourself

• Lead by Example

• Know yourself and seek self improvement

– Go to training

• Failure Modes Driven Strategy

• Planning and Scheduling

• Leadership 101

• Treat everyone equally (like you want to be treated)

• Be Technically and Tactically Proficient

• Work as a partner with Production

• Talk to Operators

• Take the Lead and Empower your Employees

Page 20: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Change your Maintenance Staff

Page 21: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Empowerment

Page 22: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

0

50

100

150

200

250

300

350

400

June July Aug Sept Nov Dec

PM

EM

Empowerment

Page 23: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Give them the GPS and let them Drive Some

Page 24: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

70-80 % of equipment failures are Self-Induced

• Putting hydraulic fluid into a reservoir without

filtering it

• Welding on equipment without grounding

properly

• Running Equipment to Failure when it is not

part of your maintenance strategy

• Aligning couplings without using a laser

• Improperly lubricating electric motors

• Not using a torque wrench

• Not Following Known Best Practices

Procedures

PM

CM / Repair

Lubrication

Page 25: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Causes of Variation

• Lack of an effective PM Program

• Lack of a repeatable repairs with

specifications

• Lubrication issues, lack of lubrication,

contamination, etc.

• Operator Error

• Use of wrong tool to make repair

– Bearing heater

• Use of wrong specification

– Torque values

Page 26: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Variation is your enemy

Page 27: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Step Number 4 – Utilize Effective Work Procedures

• Repeatable process

• Capture knowledge

• Train new employees

• Reduce / eliminate self induced failures

Page 29: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Effective Procedure Execution

Page 30: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Our Goal

Page 31: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Effective Work Procedures

What is required to ensure you have a

repeatable process?

– Step by Step Procedures

– Specifications / Standards

– Required Parts

– Potential Parts

– Special Tools (Core Drill)

– Special Equipment (60 JLG Lift)

– Craft and Number of Each Craft

– Special Permits

Page 32: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

Who writes the procedures?

Page 33: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

“Excellence is a Habit”

- Aristotle, 330 BC

Page 34: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

4 Steps to Success for Maintenance Supervisors

Step 1 – Perform a sample PM Evaluation

(free up staff)

Step 2 – Ensure Effective Work Order Information

(know what is killing you)

Step 3 – Change your Culture

(change the way you and your staff think)

Step 4 - Utilize Effective Work Procedures

(reduce variation)

Page 35: 4 Steps To Success For Maintenance Supervisors

Copyright 2010 GPAllied©

• If you want copies of the slides send me a

request

• If you want copies of the Tool Box Training

Sessions send me a request

• Questions

[email protected]

“Let’s Make a Difference”