C A S E S T U DY
OF THE
MAINTENANCE
I M P ROV E M E N T
P RO C E S S AT
AY L E S F O R D
NEWSPRINT
LT D
1. What would you suggest the strategy should be
for the role out of CMMS ?
Key requirements for CMMS improvements.
• Employee awareness is vital
• An understanding of how and why
• Security control
• Training to required levels for different personnel
• Remember “Crap in Crap out”
2. What metrics could be collected from CMMS ?
There are two type of metrics that can be collected
• Order Priority system :
– Numbering system 1 to 5 (1 is the highest priority)
– Generates Target Completion Date
– Performance measured using Work completed within the Target date
• Work Types :
Unplanned Corrective Maintenance (UCM) and Planned Preventive Maintenance (PPM) assist with
monitoring cost
Allow cost between Planned and Unplanned Maintenance to be compared to set the budget and target
3. WHAT KPI’S WOULD YOU SUGGEST ARE USED FOR THE
COMPANY TO SUPPORT AND PROGRESS CONTINUOUS
IMPROVEMENT?
Financial Metrics
• Profit: This is one of the most important performance indicators out there. Analyse both gross
and net profit margin to better understand how successful your organization is at generating a
high return.
• Cost: Measure cost effectiveness and find the best ways to reduce and manage your costs.
People Metrics
• Knowledge Achieved With Training: Helps the company see the effectiveness of employee
training. It can be determined by creating an exam and monitoring exam pass rate percent,
average score percent. If you are a larger organization, you may conduct a pre-test before
training and then a post-test after training to see specifically what was learned.
HOW WOULD YOU THINK FMEA & FMEC A COULD SUPPORT
RCM, AND WHAT ELSE COULD IT BE USED TO SUPPORT?
• Benefits:i.
Improved accuracy of CMMS and Drawings.
ii.
Refinement, deletion and creation of PM schedules.
iii.
Review of stock levels.
iv.
Produces critically value for use in Work Planning & Control.
v.
Highlights the opportunity for Operator checks.
vi.
Increases the use of Non intrusive maintenance such as Vibration Analysis
5.How Would You Suggest Implementing FMEA &
FMECA?
• Assemble team.
• Gather and review relevant information.
• Identify the items or processes to be analysed.
• Identify the functions, failure, effect, cause and controls
• Evaluate the risk associated with the issues identified by the analysis.
• Prioritize and assign corrective actions.
• Perform corrective actions and re-evaluate risk.
• Distribute, review and update the analysis, as appropriate.
Use the Risk Priority Number (RPN) method to assess risk
RPN = Severity x Occurrence x Detection