In the field of power generation, I have observed the initial stage of identifying preventive maintenance tasks required to tackle all possible failure modes. While this is a straightforward process, the challenge arises when there is an imbalance between the allocated work hours and the available workforce. It is essential to streamline these tasks to make them more manageable and efficient, ultimately reducing man-hours. For instance, I once encountered a situation where over 400 preventive maintenance tasks were established for infrared inspections on Motor Control Centers, one for each breaker. However, this number was successfully reduced to just 4 tasks, one for each unit. Achieving this level of optimization requires time and skilled personnel. Despite being effective for critical equipment, implementing a comprehensive maintenance strategy must also take into account the associated costs.
How does the power industry define preventive maintenance strategies that address all possible failure modes? Are Reliability-Centered Maintenance (RCM) methods commonly used in this context?
Initially, the maintenance team perceived Reliability-Centered Maintenance (RCM) as a way to transfer their hard-earned knowledge to less experienced, lower-paid workers, potentially diminishing the demand for highly skilled maintenance personnel. The key to overcoming their concerns was providing them with adequate time and training to understand the advantages and positive outcomes of the program. While their skepticism lessened once they grasped the benefits, it is important to remain cautious as their doubts could resurface based on how they are treated.
EPRI (Electric Power Research Institute) primarily utilized Reliability Centered Maintenance (RCM) to create standardized templates for critical equipment such as motors, pumps, and transformers. These templates outline all suggested preventive maintenance tasks, with variations depending on the machine's criticality. While some plant-specific elements and failure modes may still be overlooked, the templates generally provide comprehensive coverage.
Rob is circling back to the age-old question that many people ask: "What's in it for me?" One approach could be to propose naming them as consultants or experts in the matter.
It appears that the power industry may have the advantage of utilizing standardized templates, or EPRI is more efficient in refining maintenance strategies. This is particularly crucial for nuclear power plants to prioritize safety measures and ensure optimal operational performance.
Discover what happened during the reconnaissance mission that led to a crash. Uncover the truth behind the derogatory terms used in this situation, where there was an overreliance on whiteboard boards instead of common sense. Don't dismiss this as just another acronym - it may have more significance than you think. Are you a Signed Non Believer?
Reliability Centered Maintenance (RCM) is often dismissed as a mere myth in maintenance practices, but I successfully applied it on a small scale for an electric motor. The results were remarkable, as the preventive maintenance requirements were significantly reduced after a thorough review of all available data. RCM is a valuable strategy for transforming your current maintenance approach into more efficient and effective activities.
Through an assessment of the electric motor, I identified numerous ineffective maintenance practices that were rectified by implementing RCM-defined strategies. The client was so pleased with the outcome that they have decided to apply these principles to their other equipment as well. With the guidance of an experienced facilitator well-versed in asset equipment, we were able to achieve a successful RCM implementation, drawing upon industry best practices for reference.
By debunking the myth surrounding RCM and embracing its potential, we have revolutionized our maintenance mindset and paved the way for more streamlined and effective procedures.
Lammie, it is important to assess the quantifiable decrease in preventive maintenance tasks and manhours required post-RCM implementation. How can the reliability of electric motors be effectively measured and any improvements quantified? Have there been any noticeable increases in the reliability of electric motors, resulting in decreased maintenance costs?
- 01-11-2024
- Vanessa Carter
quote: The challenge arises when you find yourself with more preventative maintenance (PM) work hours than staff available. Ron, can you provide illustrations of the PM manhours generated by Reliability-Centered Maintenance (RCM) compared to the craft manhours you have at your disposal? While I grasp the concept of PM packaging, it may not bridge the gap between the required and accessible manhours.
In evaluating the effectiveness of Reliability Centered Maintenance (RCM), it appears to be most beneficial for the most vital equipment in power plants. However, when considering RCM as a comprehensive maintenance approach, the main concern remains the implementation costs. What constitutes the list of critical equipment for power plants? The term "beast" in relation to RCM reflects the perception of it being a resource-intensive strategy for maintenance.
- 01-11-2024
- Quentin Foster
Quoting the PM is significantly decreased after thoroughly reviewing all available data. Numerous ineffective maintenance practices were discovered prior to implementing RCM to establish maintenance strategies. It appears that your observation regarding decreased PM contradicts Ron's mention of increased PM manhours resulting from RCM. Could you be referring solely to the quantity of PMs and not the manhours needed to execute them?
Is anyone here experienced in Reliability Centered Maintenance (RCM) within the aviation industry? How do aviation companies manage the manhours required for Preventive Maintenance (PM) as determined by RCM? Are these PM manhours significantly higher than the available workforce?
Many leading oil and gas companies like Shell, BP, and Exxon Mobil have adopted Reliability-Centered Maintenance (RCM). Additionally, major power companies like EDF and China Light & Power, prominent aircraft manufacturers such as Boeing and Airbus, and various defense forces such as the UK, US, Australian Air Force, and Navy, as well as certain armies, utilize RCM. If you are interested in seeing quantified benefits, Mowbray's RCM II book includes a comprehensive appendix on the topic. It is common for readers not to comment on posts discussing RCM implementation, as clients often prefer to keep their statistics confidential. This does not indicate that RCM is not being implemented successfully, as suggested in your interpretation.
If RCM has indeed been widely adopted, how did organizations address the challenge of balancing the increased manhours required for preventive maintenance (PM) tasks compared to available craft manhours? While consolidating PMs may help with coordination, it may not significantly reduce the overall time spent on equipment maintenance.
Hey Josh, there will be a decrease in preventive maintenance (PM) and an increase in predictive maintenance (PdM) activities for specific motors. We are eagerly awaiting the results of this change after one year. I hope to create a case study based on this implementation to share with others in the future.
Find expert advice and troubleshooting tips for maintaining industrial equipment in our online forum. Discover ways to increase efficiency and productivity while reducing downtime. Join the discussion and gain valuable insights from experienced professionals.
Josh, in response to your question about how to handle the increase in PM manhours compared to available craft manhours due to RCM, it's important to distinguish between truth and propaganda. Drawing from my own experience and referencing experts like Moubray, it's been shown that total PM+CM hours can actually decrease by 25-40% with a well-executed RCM process. Additionally, uptime can increase by 1-5%, and there can be a reduction of 10% or more in Process Safety events. RCM is not just about selling a product or software; it's about improving reliability. While I personally believe in its effectiveness, ultimately the decision is yours to make.
- 01-11-2024
- Jasmine Howard
It seems that a conflict arises when RCM results in assigning more PM manhours than there are available people. Some argue that PMs do not increase and total PM+CM manhours actually decrease post-RCM implementation. Ron, what could be the reason for your PM manhours exceeding the available workforce post-RCM? Apart from an increase in the number of PMs, is it possible that your organization had a lean workforce before RCM? Or perhaps your PM approach pre-RCM was not comprehensive enough? Could it be that your list of failure modes is too extensive and exceeds what is actually needed? These factors may be contributing to the discrepancy observed in manhours post-RCM.