The first approach is to conduct a series of training programs along with hand-holding. During such programs, participants apply the concepts discussed in the programs on the critical machines to modify the existing maintenance plan or methods to improve equipment reliability over a period of time. It is effective if the organization fulfills two vital conditions. First, the organization has in place a reasonably competent condition monitoring team and the use of condition based maintenance strategy is quite widespread in its acceptance and application throughout the plant. Second, the number of failures/component replacement in the plant in a year is not more than say 60. We would call this method — The Interactive Training Method.
The second approach is a more hands-on, direct and intensely collaborative. Each critical equipment is thoroughly examined in its dynamic condition to find out its inherent imperfections that cause failures to happen. Such imperfections, once identified by deep study, are then systematically addressed eliminate the existing and potential failure modes to improve MTBF and Safety. Based on the findings, the maintenance plan is formulated or appropriately modified to sustain the gains of implementing the findings. This activity is to be done during the program. This approach is effective when the failure rate in the plant is random and high (more than 60 failures/component replacement in a year) and/or maintenance load is heavy and repetitive along with high maintenance cost in spite of having a reasonably equipped condition monitoring team in place. We would call this — The Deep Dive Approach.
Outline of the two methods: — The processes involved along with approximate costs.
The Interactive Training Method:
1. Such training sessions are conducted once every two months for a duration of 4 days each over a period of 24 months.
2. The training programs would essentially focus on the following == a) the RCM process focussed on Failure Modes b) Vibration Analysis c) Lubrication analysis and management d) Bearing failures and practical reasons e) Root Cause Failure Analysis method — FRETTLSM method. f) Friction, Wear Flow, Heat, g) Foundations and Structures. h) Condition Monitoring of Electrical failures i) Maintenance Planning based on nature of Failure Modes j) Life Cycle Costing k) Auditing RAMS (Reliability, Availability, Maintainability and Safety).that would help in self auditing the process — in total 12 programs
3. Accordingly, there would be 12 visits to the plant. During each visit one of the above topics would be covered. Once the improvement concepts are delivered, the participants (assigned for focussed plant improvement) would collaboratively engage in designing appropriate measures to improve or modify the existing maintenance plan of each critical machine to improve its MTBF and Safety. This activity that involves a fair amount of handholding would be done during the visit. Number of critical machines to be taken up for each visit would be decided by the management or participants. Number of participants = 10 maximum
4. Subsequent paid audits to refine the process would be optional — after the completion of 24 months intervention period.
The Deep DIve Approach:
Such interactive sessions would be conducted once every two months for a duration of 4 days each over a period of 18 months.
2. Each interactive session of 4 days duration would focus on one critical equipment at a time. In total 9 critical equipment would be covered during the 18 months period with a selected group of people, assigned to the project of improving reliability. During each sessions each of the critical equipment would be examined deeply and in totality to find the inherent imperfections that cause different failures in the system.Once, these imperfections are identified, time is taken to appropriately address the “imperfections” and simultaneously formulate or modify the existing equipment maintenance plan for sustaining the gains on an on-going basis. This collaborative activity would be done during the program. In this process, participants learn by doing.
3. In total there would be 9 visits to the plant. During each visit one critical equipment would be taken up for the deep dive study taken to its full logical conclusion. Number of participants = 10 maximum.
4. Subsequent paid audits of the progress is optional.- after the completion of 18 months intervention period.