World Class Maintenance Management

This is the 3rd of a series of books on World Class Maintenance Management - The 12 Disciplines that discuss about creating a solid partnership with operators. This book had to be written for industries to realize what they are missing. For as long as operators and maintenance in industries remain a separate function, Industries will continue to be reactive. This book does not only cover the principles and concept of Autonomous Maintenance, but provides the nitty-gritty details on how it is implemented starting from Step 0 to Step 7 which took me years to understand. My goal is to reach out to industries and convince them that these two cannot co-exists without each other and that it is time for both operators and maintenance to finally work together to improve not only the productivity but also the Reliability of their equipment and assets. Separating these two only creates feud and friction between them. Some highlights of this book includes: - Why Operators are Important in the Reliability Strategy- What Maintenance is all About- Survey on Top Problems of Preventive Maintenance Revisited 2018- Why Preventive Maintenance cannot prevent "ALL" failures- Operations and Maintenance - Will the Feud Ever Stop?- Reducing Human Errors in Maintenance- Why Operations and Maintenance Went their Own Separate Ways- Understanding Human Errors- The Common Thing RCM and TPM Both Believes- Strengthening Operator and Maintenance Partnership- Detailed Guidelines in Implementing 7 Steps of Autonomous Maintenance- Tips in Implementing Autonomous Maintenance- Detailed Guidelines in Implementing the 4 Phases of Planned Maintenance- Tips in Implementing Planned Maintenance- Detailed Guidelines in Implementing RCM Analysis for Equipment- Tips in Implementing the RCM Analysis- Detailed Guidelines on How to Perform Root Cause Failure Analysis Probe- Tips in Implementing Root Cause Failure Analysis- Guidelines in Conducting Equipment FMEA/FMECA- Tips in Implementing FMEA/FMECA- The Biggest Missing Link in Any Reliability Strategy- Changing the Image of the Maintenance Function- It Will Definitely Take Time for Industries to Accept- The Separation Needs to End, and a Partnership Needs to Begin- How to Strengthen Operators and Maintenance Partnership- Tips and Guidelines in Implementing TPM Focused Improvement and many more. This book explains that operators will always the first line of defense on any equipment-related failures and breakdowns since they are the closest people that will experience the failure first before maintenance.

This is the 5th of a series of books about World Class Maintenance Management disciplines about MRO Spare Parts and Storeroom. It is written for industries with MRO problems and searching for solutions to their Spare Parts and Storeroom. MRO Spare Parts and Storeroom Management is one of the most neglected maintenance strategies in any industry, which should not be the case. Others say that this is the missing link to any reliability and maintenance improvement. Almost every type of industry, whether from manufacturing, processing, pharmaceutical, power plants, mining, construction, aviation, oil, and gas, has a storeroom to keep their spare parts, but the problem is about managing and controlling them. There are two main goals of MRO Spare Parts and Storeroom, which are quite conflicting. First, this balances the cost of spares inventory and provides all the parts and supplies needed to keep the plant operating. It may sound conflicting or contradicting, but thinking about this thoroughly, it is really not conflicting if the MRO Storeroom is well managed. Second, the role of maintenance is to make the equipment available. Two of the main highlights of this book are to provide the reader an algorithm or MRO Decision Diagram to determine if a spare needs to be stock or not, and the second is to determine the correct quantity of parts to be stocked in our storeroom. Some of the highlights of this book include: -Provide a decision-making process on whether to stock or not to stock parts through an MRO Decision Diagram or Algorithm -How the MRO Algorithm or Decision Diagram is Used -What can we do about squirrel stores and how to eliminate them permanently -Different ways of analyzing MRO Spare parts -Learn the basic "Golden Law" on MRO Spare Parts Management -Learn several options on what to do for obsolete parts inside the storeroom. -Learn one option on what to do with non-moving parts -Learn why not all critical parts need to be stuck in the storeroom. -Learn important factors to consider before making a decision on whether to stock or not to stock parts in the storeroom -Learn a much better way of determining the minimum quantity to be stored besides min-max and EOQ calculation. How to address squirrel stores permanently -Provide the reader with a step by step roadmap on how to finally improve their MRO Storeroom -Understand who are the best people or function to handle the maintenance storeroom and why -Learn that one of the most important functions of the storekeeper is to maintain and care for the spare parts. -Different methods on Automating MRO Spare Parts and Storeroom -Detailed Step by Step roadmap on how to improve your storeroom -Why improving the storeroom should be done inside and outside the storeroom and many more. 99.99% of all the problems on MRO Spare Parts and storerooms are man-made, and they may come from different departments or functions of the organization. If man created the problem, let the man find the solution to their MRO Spare parts and storeroom problems. This book starts with a survey on the different problems common to industries on their MRO Spare Parts and Storeroom. As you read each chapter, it will provide the reader with a clear understanding of dealing with each of these problems. On the contrary, we cannot simply stock every single part of every piece of equipment we have in the plant if your industry still wants to remain in business.

There are cases where breakdowns and failures are not the primary cause of equipment downtime, especially in manufacturing industries. Although RCM is a popular maintenance strategy, many manufacturing industries are still not implementing this process and continue to remain stuck in their PM tasks activities. The main reason why I wrote this book is that doing RCM in a manufacturing plant is a bit different from doing RCM in oil and gas, power plants, and other similar plants because their equipment losses are different. Although the process on how RCM is done will be the same. If you worked in a semiconductor plant, breakdowns and failures are not the main issues on the machines, but minor stoppages, changeover, and quality problems are. You must know the boundary between what RCM can address and what it cannot. RCM will address failures and breakdowns by proposing maintenance tasks, it is not designed to address every possible equipment loss. What I am saying is that failures are just a subset of the entire equipment losses. Suppose you have chronic quality problems caused by the equipment, RCM can address some of them, but not all, since Quality problems and defects are much broader than breakdown and failures. I have a detailed explanation of what particular losses RCM can and cannot address in Chapter 3.3.2 of this book. This book is written to help and provide detailed guidelines for manufacturing industries on implementing RCM on their machines, equipment, and assets. Some of the highlights of this book include: - 27 Frequently Asked Questions (FAQ) on RCM- 22 Tips on Implementing RCM- 15 Don'ts About RCM- Why the RCM Preparatory Stage is Important- Detailed Guidelines in Doing the RCM Preparatory Step- Can RCM Address All Equipment Losses?- Actual Case Study on RCM: Air Handling Unit Case- Role of Operators in the RCM Analysis- How to Integrate RCM into the TPM Process- Bonus: RCM Forms I used in Excel Format- The RCM and TPM Crossroads — Do they have different or the same paths- Strengthening the SAE JA1011 Criteria- Addressing MRO Spare Parts after Implementing RCM- How to Determine the Correct Interval for PM, PdM, FFT, and Switching Standby Components- MRO Decision Diagram on Whether to Stock or Not to Stock- Difference Between a Failure Mode and a Root Cause- Secondary Tasks for Doing On-Condition Tasks- Detailed Guidelines in Writing the RCM Decision Worksheet Explained- Detailed Guidelines in Writing the RCM Information Worksheet Explained- Detailed Guidelines in performing Horizontal Replication for Similar Equipment with the Same Operating Context- Detailed Guidelines in Conducting the RCM Audit and many more...In this book, I have explained two definitions of RCM, which are looking at the equipment side and the human side of doing it. From an equipment point of view, Reliability-Centered Maintenance is a process used to determine any physical asset's maintenance tasks, decisions, and requirements in its current or present operating context. It is also a process used to determine what must be done to ensure that any physical assets continue to do whatever their users want them to do in their present operating context. On the other end, from a human point of view, RCM is a way or process of capturing and extracting the knowledge, understanding, experience, and wisdom of the most experienced people in the plant and transforming it into a living document and their legacy.