Equipment maintenance - A second chance.

equipment maintenance in a manufacturing plant

Equipment maintenance, if I could do it all over again, this is what I would do.

"After 20 Years In Maintenance And Engineering Here Is One Page On What To Do If You Are In Charge Of Asset Management In A Company!"

Actions For Immediately Improved Results.


1.      Have a lubrication regime where everything is lubricated when due and you know the right lubricant gets all the way to where it should.

2.      Have 50% of the plant or maintenance engineer�s time spent out with the maintenance trades teaching them and learning from them.

3.      Have shaft alignments are done on all pumps and gearbox drives including eliminating �soft foot�.

4.      Vibration monitor bearings on critical equipment often enough to stop a failure.

5.      Get to know vendors and supplier�s best technical people and get their advice on problem plant.

6.      Introduce equipment watch-keeping lists and trouble-shooting check sheets for plant operators.

7.      Make plant and equipment choices and selections with a 20 to 25 year time span in mind.


Actions For Improved Results That Will Show Benefits In A Few Months Time.


1.      Start measuring performance with Key Performance Indicators.  Measure both the equipment performance and the business system�s performance.  Use that knowledge to continuously improve.

2.      Establish a basic condition-monitoring regime � vibration/oil analysis/thermography/visual inspection.

3.      Perform a thorough engineer review of plant changes and upgrades to make decisions based on fact.

4.      Go outside of the company and bring in the training and teaching that your people need to become leaders in their field.

5.      Use Maintenace Planners to plan jobs in detail so you pick-up labour efficiency and job quality.

6.      Track-down all galvanic corrosion between dissimilar metals in contact and get rid of it.

7.      Teach operators how the equipment works and teach your maintenance trades how the process works.

8.      Provide all the technical knowledge on plant and equipment that your trades need, in a place they can easily find it.

9.      Do a Root Cause Analysis on equipment and systems failures.


Actions For Improvements That Will Show Benefits Over The Coming Years.


1.      Align the Capital Projects group�s output to the on-going needs of Maintenance and Operations.

2.      Show and introduce supervisors and leading hands to world class practices so they can see the benefits.

3.      Show and introduce Senior Managers to world class practices and methods so that can see the benefits.

4.      Select the best vendors and suppliers and form a long-term partnership.  This will save time, give you access to good prices, let you use their expertise to solve problems and let you focus on your business.

5.      Build flexibility and redundancy into the plant so that when something goes wrong you have options to address it quickly.  For example install tie-ins to processes in readiness to install mobile plant if the main item fails.

6.      Apply Reliability Centered Maintenance on new and old plant and equipment.

7.      Select and use equipment that does not breakdown when it fails.  Design protection into equipment that stops it breaking if it�s overloaded or run wrongly.

 Best regards,

Mike Sondalini.

Feed Forward UP-TIME Publications teaches your maintenance crew engineering and asset care knowledge so that they can solve more problems, become more knowledgeable, make better decisions and your plant runs more reliably!

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