Hello everyone, I am in the process of creating training materials focused on maximizing Preventive Maintenance effectiveness in various industries. I am looking to gather insights from you regarding the common problems faced during Preventive Maintenance (PM) activities. I have outlined some key issues based on my knowledge and feedback received thus far. Here are the top concerns identified through a survey conducted on May 26, 2008: 1) PM Checklists Syndrome - where PM checklists and tasks continue to expand (2 votes) 2) Infant Mortality Failures - situations where issues arise post PM replacement or overhaul (1 vote) 3) Replacement of functioning parts to align with PM specifications and processes 4) Random Failures - unanticipated breakdowns included in PM checklists (1 vote) 5) Aging workforce approaching retirement 6) Inadequate training on maintenance processes (3 votes) 7) Operational dependence on reactive maintenance despite established PM programs (3 votes) 8) Frequent plant reorganizations leading to new systems under new management 9) Poor or insufficient documentation for PM procedures (2 votes) 10) PM waivers - Operations bypassing PM for production requirements (1 vote) Please select the top 3 issues that stand out to you (e.g., 1, 2, and 4). As we gather more insights, we can collectively develop recommendations for these identified challenges. Your participation and input are greatly appreciated. Thank you for your involvement. Warm regards,
Greetings to everyone! Drawing from my past experience in the manufacturing industry, a common issue encountered during preventive maintenance (PM) is as follows: 1) the phenomenon of an ever-expanding PM checklists and activities; 2) Infant Mortality Failures, referring to problems emerging post-PM replacement and overhaul; and 3) PM being waived by operations to meet production demands. With warm regards,
Dear all, I encourage others to join in and participate in this survey. So far, I have shared it with a few of my contacts and here are the initial results. Despite our different geographical locations, we may be facing similar issues. Updates will be posted in the main thread. Please note: I apologize for any oversights in this survey. If you wish to participate without disclosing your industry, please email me at rollyangeles@rsareliability.com. Your response will be kept confidential, with only the votes being shared without any names or industries attached. Thank you for your participation. Warm regards, Rolly Angeles.
Hey Rolly, have you given the "Poll" feature a try from the New button for conducting your survey?
Dear Josh and All, Thank you, Josh, for your suggestion, but I believe it would be more beneficial for me to conduct this survey manually. Currently, I have received responses from 10 individuals, and it is intriguing to see that the number continues to increase steadily. I have decided to set a deadline for the survey, which will be on June 2, 2008. The results will be shared on this forum by June 3 or 4, 2008. In order to maintain confidentiality, only the total number of participants and the survey results will be disclosed. The identities of the participants and their respective industries will be kept private. Recognizing the significance of this survey, I urge everyone to participate. If you would like to take part, please send an email to rollyangeles@rsareliability.com. I am confident that the insights gathered from this survey will be valuable to all of us in the realm of reliability. Your involvement is greatly appreciated. Warm Regards,
Numbers 2, 3, and 9
In my experience, I would say the top three issues impacting Preventive Maintenance effectiveness that you've listed would be 3, 6, and 7. Replacement of functioning parts to align with PM specifications can lead to unnecessary expenses and resource drain. I believe the root of that, and potentially many other PM issues, could be traced back to inadequate training on maintenance processes. Lastly, operational dependence on reactive maintenance seems particularly counterproductive to the ultimate goal of PM. This can lead to higher costs, unexpected downtime, and overall inefficiency. It's important to advocate for a more proactive, rather than simply reactive, approach to maintenance.
Hello, it's refreshing to see someone tackle the optimization of Preventive Maintenance! From my experience in power plants, the top three issues that stand out are 1) PM Checklists Syndrome, 3) Replacement of functioning parts to align with PM specifications and processes, and 7) Operational dependence on reactive maintenance despite established PM programs. It seems that often the checklists become overwhelming, leading to shortcuts, and the replacement of functioning parts can sometimes feel counterintuitive but we do it anyway just to align with the PM schedule. Furthermore, despite having a strong PM program, there tends to be a fallback to reactive maintenance, largely due to ingrained attitudes and perhaps a lack of faith in the PM effectiveness. Looking forward to seeing how this project develops!
In my experience, I'd rank 3), 6), and 7) as the most prevailing issues. The replacement of functioning parts, even when they comply with PM specifications, can lead to unnecessary downtime and additional costs. Inadequate training generally hinders the smoothing running of any PM program, creating a heavy reliance on reactive maintenance. The failure to train new employees adequately and to pass on the knowledge from an aging workforce could be a ticking time-bomb for many organizations. Interested to see others' perspectives.
From my personal experience, I would say 1, 6, and 9 are the top issues. The expanding checklists (1) can actually become counterproductive, cluttering the process with potentially unnecessary tasks. Training (6) is certainly paramount, as maintenance processes can be complex and nuanced. The better trained our personnel, the more effectively they can carry out their responsibilities. As for insufficient documentation (9), that’s a problem not just for new personnel learning the ropes but also for experienced ones who may need to refer back to procedures from time to time. Clear, thorough documentation is key for efficient and effective PM.
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✅ Preventive Maintenance
✅ Inspection Report
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Answer: - The top concerns identified through the survey include PM Checklists Syndrome, Infant Mortality Failures, Inadequate training on maintenance processes, Operational dependence on reactive maintenance, Poor or insufficient documentation for PM procedures, and PM waivers.
Answer: - To maximize PM effectiveness, it is important to address issues such as expanding PM checklists, handling infant mortality failures, providing adequate training on maintenance processes, reducing operational dependence on reactive maintenance, improving documentation for PM procedures, and preventing PM waivers.
Answer: - Addressing the aging workforce approaching retirement is crucial to ensure knowledge transfer, continuity in maintenance operations, and the development of new talent to sustain PM effectiveness in the long term.
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