MAINTENANCE

Steps to improve plant maintenance

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 Objective:
• Recognize the steps to improve plant maintenance.

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 INTRODUCTION

Finding new ways to improve

plant maintenance is always
on the mind of every
maintenance manager. In its
most basic form, plant
maintenance is the
application of best practices
to increase equipment up
time in manufacturing
facilities.

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 Main objectives of plant maintenance

The main goal of plant maintenance is to ensure the conditions in which a

plant can reach peak productivity while keeping the maintenance costs as
low as possible.

✓ Keeping assets in peak operating condition.

✓ Minimizing the chance of unplanned machine breakdowns.
✓ Shortening the length of scheduled downtimes.
✓ Maximizing the useful life of plant equipment and machines.
✓ Ensuring a safe working environment.
✓ Minimizing overall maintenance costs.

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 Steps to improve plant maintenance

Do a detailed check of your Create preventive maintenance

critical assets checklists
Clean out your deferred Review reports finding new places
maintenance backlog to improve plant maintenance

Detailed equipment, tools, and Communicate order changes and

inventory control delays with your vendors
Get informed and improve your
Implement delayed improvements
skills
Review and update your
Help technicians improve
documentation

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 1. Do a detailed check of your critical assets

If you have the needed parts and tools for a

thorough cleaning, inspection, and servicing
it’s the best time for any big planned repairs
that require shutdowns. If your technicians
have plenty of time on their hands, you could
also consider doing things like stress testing,
checking and calibration of condition
monitoring sensors, reviewing if all safety
equipment is in place and working correctly.

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 2. Clean out your deferred maintenance backlog

Since there are fewer routine PM tasks and no unplanned breakdowns

while the production is on hold, this is the perfect time to clear out your
deferred maintenance backlog. If the list is long, decide which tasks
should be a priority. When you’re done, send out Work Orders (WO)
and let your technicians get to work.

Before you assign those Work

Orders, cross-check your spare
parts inventory to ensure the
technicians have everything they
need to actually get the job done.

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 3. Detailed equipment, tools, and inventory control

It might be hard to do an accurate

control in bigger maintenance
departments where equipment and tools
are constantly going in and out of the
storage. This could also be a good time
to clean and reorganize where you keep
and how you store all of your inventory
and frequently used tools, especially if
workers tend not to put these things in
the same place they have found them.

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 4. Implement delayed improvements

The best improvements you can make right now are those you had to
delay because you were busy fixing breakdowns and doing routine
maintenance work.

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 5. Review and update your documentation

Being a maintenance manager is a lot of work. We all know that the

documentation should be up-to-date, but when maintenance
technicians are getting by with existing procedures, other work often
takes precedent.

▪ Standard operating procedures (SOPs)

▪ Emergency operating procedures (EOPs)
▪ OSHA guidelines

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 6. Create preventive maintenance checklists

Even if you’re not running preventive maintenance, you should still be

running some proactive tasks like occasional inspections and oil and filter
changes. If you are still relying on reactive maintenance, creating preventive
maintenance checklists for the tasks you do perform on a regular basis could
be a great way to start moving towards preventive maintenance.

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 7. Review reports finding new places to improve
plant maintenance
❑ MTTR and MTBF
To find places for improving your
plant maintenance, you need to ❑ Overall Equipment Effectiveness (OEE)
be able to measure how your
❑ Planned Maintenance Percentage
team performs and what are the
results of their actions. To be ❑ Overview of Total Maintenance Costs
able to do that, you need to track
relevant maintenance metrics.
By “tracking”, we mean going
through asset history,
maintenance logs, reports, and
other historical data.

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 8. Communicate order changes and delays with
your vendors

There are some companies will have a

much easier time doing this than most
others. The reason for that is that vendor
management feature lets you save all
important information in one place (names,
addresses, emails, phone numbers,
contract, parts supplied, purchase
history…).

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 9. Get informed and improve your skills

This downtime can be a much-needed opportunity to inform yourself about:

o The latest news and trends in the maintenance industry.

o The latest tools in the maintenance industry.
o The latest software solutions in the maintenance industry.
o The missing gaps in your personal knowledge base.
o Development of plan maintenance management system.

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 10. Help technicians improve

It is a common misconception that maintenance technicians don’t bring

much value if they are not out there working on your assets. While it is
true that they can’t add direct value from their homes, they too could
work on building some future value. For example, participate in online
training courses and workshops could help them to have a positive effect
on your plant maintenance.

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 Let’s practice: True or False?

1) It’s important to have the needed parts and tools for a detailed
inspection and servicing.
a. True
b. False

2) The best improvements you can make should be fixed and planned.
a. True
b. False

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 3) A maintenance manager doesn’t have a lot of work.

a. True
b. False

You need to be able to measure how your team

4) performs and what are the results of their actions.

a. True
b. False

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 ✓ Now you can recognize
the steps to improve plant
maintenance

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 Conclusion

Plant maintenance can benefit

any industrial or manufacturing
equipment, and keep it in good
working condition at the lowest
possible cost.

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