Hello everyone, I am a new member here and I'm looking to share some ideas with you all. In July, I was brought on board by my company to establish and oversee a maintenance program for 3 steel fabrication shops. While there were some existing programs in place, they weren't up to par. With just myself and one other employee on the maintenance team, we were stretched thin trying to handle all the preventive maintenance tasks. I decided to delegate some responsibilities to the operators and have been exploring new maintenance techniques and philosophies ever since. Thankfully, my boss has been supportive of my suggestions for equipment like an IR camera and Ultrasound. Setting up this new program has been a bit daunting, but I have prior experience in Preventive Maintenance from my time in the Navy. I believe we need a more efficient system that can be managed by a small team. Having a fresh start to work with is a great opportunity, although it does come with its own challenges. My plan is to focus on implementing the PM program first, investing in new equipment, and gradually making improvements. I would appreciate any advice, success stories, or lessons learned that you may have to share.
Hello Bill, I am fascinated by your situation. Running three fantastic shops surely requires a substantial amount of equipment. How did the previous person in your position maintain them so well? Fortunately, my boss was very supportive when I asked for an IR camera and ultrasound equipment. They didn't react negatively to the potential costs, which was a relief. Do you think your boss is comfortable with only two people handling maintenance? Involving operators is beneficial, but eventually, you will need more than just basic maintenance tasks. In my opinion, investing in an asset register, creating a list of tasks provided by equipment vendors, and establishing a preventive maintenance program should be your immediate focus. Don't rush into purchasing IR cameras or vibration monitoring equipment just yet. Instead, prioritize building a solid foundation with proper processes, well-trained staff, and efficient procedures. Implementing an effective maintenance plan will take time and effort but will pay off in the long run. Ensure you have a well-balanced schedule for tasks like equipment cleaning, lubrication, bolt tightening, and protection against environmental factors. Additionally, make sure you have a dedicated team of skilled maintenance workers to carry out these tasks efficiently and on schedule. While it may be tempting to invest in fancy gadgets, remember that your main focus should be on developing your processes, people, and procedures. This will ultimately lead to better results in both the short and long term. Once you have established a solid maintenance foundation, you can consider more advanced tools and strategies. For now, focus on taking small steps towards improvement rather than trying to do too much too soon. V.Narayan.
Bill, if you are looking to improve safety and environmental practices at your plant, consider implementing a safety program with training and MSDS guidelines. Develop a tagging/lockout procedure for equipment maintenance and check safety equipment like guards and switches regularly. Monitor air, water, and waste leaving your plant to ensure compliance with site plans. Review the MSDS for materials brought into the plant and establish a work order system for maintenance requests. Prioritize tasks using a system like the RPM method and set up a PM program for equipment maintenance. Centralize spare parts and create a folder for each piece of equipment containing important information. For more tips on managing maintenance efficiently, check out "Wrench Time" by Fred J. Weber, P.E. utilizing the RPM method. Visit http://www.wrenchtime.com for more details.
Bill, as a predictive maintenance consultant who relies on vibes, I echo the valuable advice given by Vee and Fred. Rather than diving straight into advanced diagnostic techniques, take the time to assess your workload and strategy first. Once you have a clear understanding of your needs, incorporating diagnostic tools can help you save time in the long run. It's important to remember that mastering these tools often requires specialized training and skills that are not easy to acquire on a part-time basis. Unless you plan on regularly performing tasks like IR or Vibration analysis, you may struggle to excel in using these tools. Wishing you the best of luck in your endeavors.
Bill, involving operators in the maintenance process is crucial for successful implementation of new programs such as TPM and RCM. It is important to gain buy-in from both management and machine operators. One effective way to get management on board is by showcasing cost-saving projects, such as monitoring energy usage before and after machine alignment. By identifying and solving issues that impact productivity, you can demonstrate tangible benefits to upper management and gain their support. When it comes to engaging operators, targeting a resistant individual and persuading them to embrace new ideas can encourage the rest of the team to follow suit. Additionally, subtly leading people to a decision as if it were their own idea is a tactic that can be effective, especially with self-absorbed managers.
Looking for advice on persuading a stubborn and opinionated senior citizen? While talking to people is always helpful, convincing those who listen but remain unconvinced can be a challenge. How can you effectively sway someone set in their ways?
Hi and welcome to the forum! It sounds like you've got your hands full, but also that you're taking a calculated approach to this project which is impressive. Drawing from my experience, I have found the use of Computerized Maintenance Management Systems (CMMS) to be extremely effective for managing maintenance tasks with a small team. It lets you schedule, assign, and keep track of maintenance work, making it less likely for anything to slip through the cracks. I also recommend regular training for the operators, not just in their new responsibilities, but in understanding the importance of their role in maintenance. This will help foster a preventive culture in your workplace. Excited to hear about your progress in this. Good luck!
Welcome to the forum! It sounds like you're diving into an exciting challenge, and your Navy background should definitely give you an edge in creating an efficient maintenance program. Delegate wisely, as you mentioned—empowering operators can really enhance accountability and often leads to valuable insights from those who work directly with the equipment. Have you considered implementing a computerized maintenance management system (CMMS)? It could streamline your preventive maintenance scheduling and tracking, which might free up some of your team’s time for those other important improvements you're looking to make. Best of luck, and I’d love to hear about your progress!
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Answer: - Some common challenges include inadequate existing programs, limited manpower, difficulty in handling preventive maintenance tasks, and the need for efficient systems managed by small teams.
Answer: - Operators can be delegated responsibilities within the maintenance program, which can help alleviate the workload on the maintenance team and ensure a more comprehensive approach to maintenance.
Answer: - New techniques such as using an IR camera and Ultrasound for equipment maintenance can be explored to enhance the effectiveness of the maintenance program.
Answer: - Prior experience in Preventive Maintenance can provide valuable insights and strategies that can be applied to improve the efficiency and effectiveness of the maintenance program in steel fabrication shops.
Answer: - It is recommended to focus on implementing a PM program first, investing in new equipment, and gradually making improvements to create a more efficient and manageable system for maintenance.
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