Hello everyone, I'm curious about the PM optimization strategy that is being widely discussed. After downloading numerous resources from different websites, it seems like a promising approach for organizations looking to quickly implement a reliability-centered strategy. Can someone provide more insights on this topic? Thank you -gspal
Hello gspal, PM Optimization (PMO) is a valuable tool used in two main scenarios. Firstly, it is utilized for enhancing and validating existing PM tasks within a maintenance program by reconstructing the technical basis of each task. Secondly, it is employed to re-analyze implemented PM recommendations that originated from the process of Reliability Centered Maintenance (RCM). PMO is a focused task-based analysis effort that specifically targets equipment covered by the current PM program. The program consists of two phases, with the initial phase concentrating on evaluating the effectiveness of the current PM tasks in addressing critical equipment functions and failure mechanisms. The second phase is triggered in cases where RCM was not initially conducted, and it involves a screening process to identify equipment of Functional Significance (FSI) outside the current program, utilizing RCM principles. This phase serves as a quick method to establish a solid foundation for the existing PM program before considering a traditional RCM program. Businesses experiencing high rates of PM cancellations or have accumulated a significant number of PM tasks over time find the PM Optimization process particularly beneficial. It can also be used as a pilot process to showcase the effectiveness of optimizing PM tasks and convince management to invest in a comprehensive equipment reliability program. If you haven't already visited our website, we have two papers detailing a PMO project conducted in the 90s, which were presented at SMRP conferences. For more information, please refer to the PM Optimization Papers on our website. Thank you!
Hello Larry, the documents indicate a notable decrease in the number of preventive maintenance tasks (PMs). Can we also determine the percentage reduction in manhours or costs associated with performing these PMs? Thank you.
Hello Josh, I wanted to provide some background information on the facility. With 25 years of operation, the facility had accumulated too many PMs over time, causing management to lose interest in classical RCM due to slow ROI. Because the facility operates in a highly regulated industry, they were unable to postpone or cancel their PMs, resulting in excessive overtime for the craft workers. Here are the outcomes of the changes implemented: 1.) The number of corrective maintenance work orders stayed consistent over a six-year period. 2.) There were no unplanned shutdowns for six years. 3.) Budgeted Hours Pre-Analysis: Elect - 9,000, Mech - 19,000 Post-Analysis: Elect - 2,700, Mech - 4,300 4.) Overtime was completely eliminated. 5.) The craft workers had the opportunity to receive training in predictive maintenance techniques such as vibration analysis and thermography, and were able to share their expertise with other facilities within the company. Regards,
Hello Larry, I have some questions regarding the elimination of overtime. Shouldn't overtime be optimized to a best practice of 8% rather than completely removed? By optimizing preventive maintenance practices, we can detect equipment deteriorations more effectively, leading to more proactive rectifications. How do you evaluate the effectiveness of these proactive actions? Thank you.
Hello Larry, I am concerned about the current state of uptime and technical integrity. Have you been monitoring any changes in these aspects? - V. Narayan (Vee)
Absolutely, gspal! PM optimization, or Preventive Maintenance optimization, is a thorough assessment of an organization's current maintenance strategy to find areas that can be improved. It involves determining the optimal intervals for maintenance tasks, and finding inefficiencies in tasks that could be causing unnecessary downtime. Ultimately, it's about achieving the highest level of reliability at the lowest cost. A well-implemented PM optimization not only reduces downtime, but also extends the life of equipment, thus saving costs in the long run. It's an ongoing process and needs to be reviewed periodically since things change over time with improvements in technology, equipment, and processes. So, for any organization looking to boost their reliability-centered strategy, PM optimization can be a game-changer.
Absolutely, gspal! PM optimization is indeed an effective strategy for organizations focused on reliability-centered maintenance. At its core, it aims to find the sweet spot between running equipment to failure and spending excessive resources on unnecessary maintenance. By balancing these factors, PM optimization can reduce wastage and improve system reliability. However, it's not a one-size-fits-all solution. Each organization must tailor it to their unique needs, factoring in elements like equipment age, operation criticality and even the local environment to get the most out of PM optimization.
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Answer: 1. What is PM optimization strategy and how can it benefit organizations? - PM optimization strategy involves enhancing maintenance processes to improve efficiency and effectiveness. It can benefit organizations by reducing downtime, increasing equipment reliability, and lowering maintenance costs.
Answer: - A reliability-centered strategy focuses on proactively identifying critical assets and optimizing maintenance schedules based on their importance. This differs from traditional approaches that may rely on fixed schedules or reactive maintenance.
Answer: - Key steps may include conducting a thorough asset assessment, prioritizing critical equipment, developing optimized maintenance plans, implementing a reliable CMMS system, and continuously monitoring and adjusting the strategy based on performance data.
Answer: - Organizations can explore industry best practices, attend training sessions or webinars on maintenance optimization, leverage software tools for predictive maintenance, and collaborate with experts or consultants in the field.
Answer: - Success metrics for a PM optimization strategy may include reduced downtime, increased equipment reliability, cost savings, improved maintenance efficiency, and overall increased productivity within the organization. Regular performance monitoring and KPI tracking can help measure the effectiveness of the strategy.
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