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admin | Category: Exercise Gym | 23.01.2015
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Environment: providing an environment conducive to giving relaxing and professional service. Convenience: offering clients a wide range of services in one setting, and extended business hours.
Reputation: reputation of the owner and other "beauticians" as providing superior personal service.
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This article explains what makes the difference between an ordinary maintenance plan and a good, effective maintenance program. Maintenance practitioners across industry use many maintenance terms to mean different things.
Maintenance strategy – Next level down, typically reviewed and updated every 1 to 2 years.
Maintenance program – Applies to an equipment system or work center, describes the total package of all maintenance requirements to care for that system. Maintenance checklist – List of maintenance tasks (preventive or predictive) typically derived through some form of analysis, generated automatically as work orders at a predetermined frequency.
Figure 1 below describes the flow of maintenance information and how the various aspects fit together. The large square block indicates the steps that take place within the computerized maintenance management system, or CMMS. It is good practice to conduct some form of analysis to identify the appropriate maintenance tasks to care for your equipment. The analysis will result in a list of tasks that need to be sorted and grouped into sensible chunks, which each form the content of a checklist.
The most obvious next step is to schedule the work orders generated by the system into a plan of work for the workshop teams.
Less common, however, is to use this checklist data to create a long-range plan of forecasted maintenance work. A logical response to this shop floor feedback is that the content of the checklists should be refined to improve the quality of the preventive maintenance, especially to prevent the recurrence of failures. A common mistake however, is to jump straight from the work order feedback and immediately change the words on the checklists.
The far better approach to avoid this guessing game is to route all the checklist amendments through the same analysis as was used originally to create the initial checklists.
Finally, all the information that gets captured into the CMMS must be put to good use otherwise it is a waste of time.
Without describing the complete RCM analytical process, it is instructive at this stage to point out a few details that are important to the content of such an analysis because of the way they can impact the overall maintenance plan. In addition to that, there is value in constructing a hierarchy of the equipment system showing assemblies, subassemblies and individual components. Of vital importance is the clear identification of the root cause of each failure, as this will affect the selection of a suitable maintenance task. Also important from a planning perspective is to identify the time it will take to carry out each task independently.
All of the above depends on the production process and the site’s operating context, so these comments should be taken simply as a guideline. In order to smooth the PM workload, a robust approach is to base the spread of PM activities on the checklists arising from the RCM-style analysis.
It is important to notice that just because two checklists may have the same frequency, it is not necessary to schedule them to be done at the same time. In order to achieve this smoothed workload pattern, it may be necessary to return to the timings, frequencies, groupings, start dates, etc., that were specified in the original analysis and rework some of the data. It is well-recognized in modern maintenance circles that there is great value in planning the maintenance workload at a macro level over a long-term horizon as well as at a detailed level over a short horizon. Regular work orders are created automatically in Maximo every night from the work order templates in the PM Master table. If possible, it would be preferable to retain all the raw data within the CMMS and simply produce all the graphs and reports from that environment. Very few CMMS packages will capture or provide the full spectrum of data that may be required to construct the desired selection of graphs. The alternative solution, therefore, is to copy the required selection of data from the CMMS to the spreadsheet environment where it can be manipulated further.


Some sites enjoy the luxury of having regular, fixed maintenance windows built into the production plans.
The generation of a long-range maintenance plan that shows the number of hours of preventive maintenance work to be done in each work center over an 18- to 24-month horizon is a valuable tool. The nature of the production environment at the author’s site makes it difficult to implement a regular, fixed pattern of maintenance windows as described above. Table 2 below illustrates what the structure of a long-range maintenance plan might look like. Based on this report, the production planners make the necessary allowances in the production calendars so that the equipment will be made available for maintenance. This arrangement of the numbers can also be used to help smooth the workload across the weeks by adjusting the due dates of the maintenance tasks in the CMMS as described earlier. The above explanations describe how to identify the anticipated number of maintenance hours in a production area. In order to ensure that each team on site has adequate craftsman resources available to cover all the work that will arise in their areas, a long-range workload vs.
If the long-term prediction shows that the level of maintenance activity is about to increase beyond the level that can be accomplished with the existing resources, this advance warning will ensure that there will be sufficient time to recruit and train additional resources before the situation goes out of control. The preventive maintenance hours from the CMMS are obtained from the totals from the long-range maintenance plan described in the previous section. Manpower is basically the effective number of man-hours available for each craft in the crew. Feedback information returning from the shop floor, either by way of the planned work order responses, or from equipment failures will be captured in the CMMS. Ideally, the engineer should look at every work order that was raised in his area, but this is not always feasible, so a summary report such as this is useful. The algorithm shown in Figure 6 below describes the thought process that should be going through the minds of the reliability engineers every time they review the failure work orders as shown on the summary report in Figure 5 above. If a spreadsheet has been identified as the most appropriate option, then it should be structured in a robust and user-friendly fashion. The purpose of maintenance measures should be to monitor the health of the maintenance organisation. The graphs in Figure 7 below illustrate some of the benefits that have been realized on the author’s site as a result of having a well-functioning maintenance organisation. Graphs 2 and 3 show how the number of failures has been decreasing month-on-month in one particular work center over the past 12 months, and correspondingly, the mean time between failures has been increasing over the same period. The last 2 graphs show machine availability in two of the key work centers where a full re-analysis of all the maintenance requirements was recently conducted using an adapted RCM2 approach. Yahoo , Facebook , Facebook , Twitter , Twitter , Google+ , Google+ , Myspace , Myspace , Linkedin , Linkedin , Odnoklassniki , Odnoklassniki , Vkontakte , Vkontakte , Google , Google , Yahoo , Yahoo , Rambler , Rambler , Yandex , Yandex , Gmail , Gmail , Yahoo! Designers Manufacturers , ??????? ????????? - ?????????? ???????????? , Gorgian Wikipedia - Free Encyclopedia , ????????? ?????? ????????? , Cambridje Dictionary Online , ????????? ???????? ????????? ?????? ????????? , Oxford Advenced Learner's Online Dictionar? , ??????????? ?????? - moazrovne,net, ??? We will also maintain a friendly, fair, and creative work environment, which respects diversity, ideas, and hard work.
Curley, and her talented team of beauticians, has what it takes to make this venture an extremely successful one.
This loan will be paid from the cash flow from the business, and will be collateralized by the assets of the company, and backed by the character, experience, and personal guarantees of the owners. With 500 complete sample plans, easy financials, and access anywhere, LivePlan turns your great idea into a great plan for success. But creating a comprehensive maintenance program that is effective poses some interesting challenges. So to level the playing field, it is necessary to explain the way in which a few of these terms have been utilized throughout this document to ensure common understanding by all who read it.
Sometimes it may be necessary to do some smoothing and streamlining of these groups of tasks in an iterative manner. Feedback from these work orders, together with details of any equipment failures, is captured in the CMMS for historical reporting purposes. When this happens, the integrity of the preventive maintenance programme is immediately compromised because the revised words on the checklist have no defendable scientific basis. This helps to keep track of which section of the system is being considered at any time, and the list of components also helps to identify the spare parts requirements for the system. The sum total of these task times gives a good indication of how long the total work order will take.
This assumes that the analysis has been conducted thoroughly and that it is in a format that can be amended easily. Sometimes, of course, it does make practical sense to schedule PMs for the same day, but don’t assume that this is always true. These fresh work orders are generated typically 30 days prior to the Target Start date specified on the PM. Because engineers like to see things in a graphical or pictorial representation, however, it may be necessary to combine the use of the CMMS with another package that has graphics capability, such as a spreadsheet.
For example, it could be agreed that every Tuesday morning Production Unit 1 will stop production and the equipment will be made available to the maintenance crew for six hours.


It gives the production schedulers visibility of the amount of time that is required for this preventive maintenance so that they can proactively plan to release the equipment for those periods.
For this reason a long-range maintenance plan is produced to give the production teams as much advance warning as possible of the anticipated maintenance requirements. A flat file is created from the master data table in Maximo which contains details of all the maintenance tasks and checklists with their corresponding equipment details, duration, frequencies, crafts, next due dates, etc. This next section covers the approach to verifying that there is sufficient manpower available to carry out all the work. Similarly, a decrease in the predicted level of maintenance activity will give sufficient advance visibility of the opportunity to reassign craftsman resources to other teams or activities.
The allowances for breakdowns, corrective work, etc., are calculated as a rolling 12-month average of the demonstrated actual data from the CMMS.
Where the workload exceeds the manpower, it will be necessary to reduce some of the non-essential activities at that time, or increase the people availability. The reliability engineer must then decide on the appropriate course of action in response to each failure or observation. Amending the checklists without running through the method and structure of the original analysis is a mistake. If it is clumsy to update, it will fall into disrepair, and the integrity of the program is lost. Where everything is in control, the metrics will reflect the success that has been achieved. These graphs form just part of the regular reporting metrics by which the maintenance activities are managed. The target is set at 95 percent and is consistently being exceeding across all of the engineering teams. It is clear to see how, in both cases, the equipment availability was far out of control and from the time the improvement activity was started, the availability stabilized and is now still tracking consistently above 90 percent. The demand from the owner's clients, as well as the ambitions of the owner to one day start her own salon, and the procurement of highly professional and qualified beauticians to support the salon, has made this business one of great potential. We expect our growing reputation to lead to new clients and beauticians to support our anticipated growth. It would be difficult to appreciate the subtleties of what makes a maintenance plan effective without understanding how the plan forms part of the total maintenance environment.
It must be emphasized, however, that this is the author’s preferred interpretation of these terms, and should not necessarily be taken as gospel truth. Implicit in this approach, however, is the need to have a robust system in which the content of the analysis can be captured and updated easily. As a general rule, in an automated or continuous process production environment, the total amount of work on one checklist or work planned for one maintenance period should not exceed 80 percent of the total time available. Other work orders are also created manually by the system users, such as craftsmen and engineers. During this six-hour window, the maintenance crew has the opportunity to assign as many people as required to complete all the planned maintenance activities in that work center. Unfortunately, this is very often reduced to the maintenance department begging for access to the equipment. This plan shows the forecasted maintenance hours for each operating unit, by craft type, in weekly chunks over a 24-month horizon. This information is imported into a spreadsheet, which uses a series of filters and formulae to produce the long-range plan. The exact dates and times for maintenance will be agreed in the week or two before it is due.
This amounts to a graph that compares the hours of work to be done each month with the corresponding man-hours of labor available.
Where the workload exceeds the labor capacity, the load must be smoothed, or additional resources may be required. The key recipients of these reports are the reliability engineers who look after each equipment system. Regardless of the approach that has been used to record the original analysis, it is worth it in the long run to force the reliability engineers to route every amendment through the analysis and record the results for future reference. Conversely, they should also be used to highlight problem areas and irregularities in order to drive the desired behaviours or areas for improvement. There could be several root causes of this failure mode that can be addressed in different ways through the maintenance program. All these work orders need to be prioritized according to the importance and urgency of the tasks, and they need to be planned into the weekly workload of the maintenance crews to ensure that a well-balanced selection of work is assigned to each crew without them becoming overloaded. Furthermore, this plea is often met with the unsympathetic response from the production teams that they have to run the equipment in order to meet their targets and they therefore cannot afford to release it for maintenance. A graph is constructed for each craft group within each workshop team, spanning the next 18- to 24-month horizon.



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