Machinery Lubrication magazine published by Noria Corporation
Issue link: https://www.e-digitaleditions.com/i/1005929
www . machinerylubrication.com | July - August 2018 | 25 deliberately sets out to do something, but what they do is inappropriate. e intended error can be either a mistake or violation. A mistake is a misapplication of a good rule, an application of a bad rule or an inap- propriate response to an abnormal situation. A violation is when someone knowingly and deliberately commits an error. Procedures help to address unintended errors and mistakes but not violations. By accounting for the different ways activities are performed, the types of mistakes made and utilizing a feedback cycle, procedure-based maintenance takes the knowledge from all the craftspeople and incor- porates it into the procedure. e result is the safest, most efficient and reliable way to complete the task. How Procedures Impact Reliability Once procedure-based mainte- nance is in place, the operation will see noticeable improvements in five key areas: safety, reliability, start-up failures, mean time to repair and knowledge management. Safety will improve as tasks are well planned out with the risks iden- tified. is allows the development of effective risk-reduction activities. Also, the procedures can be used in the event of a failure, which can lower the risks associated with unplanned work. Reliability will increase as tasks are completed consistently with proper technical specifications. is reduces premature failures. In the event a failure occurs, it can be analyzed to determine the root cause, since the procedures and activities are defined and consistent. Start-up failures will decrease, as procedures will ensure that all bolts are tightened properly, the area is inspected, all foreign objects are removed, and proper commissioning activities are performed. e mean time to repair will be reduced, as a procedure is available that will decrease the time to repair and all the required information is readily available. K nowledge ma na gement is another benefit of procedure-based maintenance. With this approach, the experience and knowledge of veteran craftsmen can be captured in procedures and transferred to junior craftsmen. Getting Started in Procedure-based Maintenance Procedure-based maintenance is used by many industries that require high uptime, such as nuclear power, nuclear navy and aviation, to name a few. But just because these industries use it doesn't mean you can't. Here is what you need to get started in procedure-based maintenance: Start by documenting the steps to complete preventive mainte- nance (PM) tasks. Walk through every task and document each step of the procedure, including any specific technical specifications. Once t he procedure ha s been developed, review it and ma ke sure it represents the best practice in completing the task. is may take many revisions or reviews. e procedure may be developed by a senior craftsperson, a planner or by having recent retirees come back to provide the information. Create a checklist that can be used when completing the proce- dure. Check lists a re employed in all major industries as a way to make certain that nothing is missed. ere may be pushback in utilizing a checklist, as craftspeople may say they are skilled. However, doctors and pilots use them to ensure nothing is missed, so why shouldn't craftspeople? Def ine a training and certi- f ication program for the new procedures that will require crafts- people to be trained on the task and procedure-based maintenance before being allowed to perform critical activities. This training should be performed by the indi- vidual(s) responsible for developing the procedure. Once the craftspeople have been trained, reinforce the use of the procedures. Conduct audits to verify that they are followed and that only trained personnel are using them. Try to reward those who embrace procedure-based maintenance. A lso, utilize the feedback provided on the procedures. is does not mean taking all feedback "One of the most difficult parts of implementing procedure- based maintenance is the change it brings to an organization." "Well-written procedures eliminate misinterpretation and drive clarity. " ML