| Client: Major Chemical Processing Facility |
Client Success Stories
Charles Brooks Associates, Inc
| BACKGROUND: Production requirements always took precedence over scheduled maintenance activities. Lack of communication between the maintenance department and the production departments. Production had lack of faith in maintenance being able to “help” them. A high level of contractors performing maintenance work. Preventative Maintenance routines were found to be substandard due to the lack of detailed procedures. SURVEY: Charles Brooks Associates conducted a brief analysis which revealed: The current Computer Maintenance Management System (CMMS), MP2, was completely under utilized; Maintenance activities were almost entirely reactive; No records of or plans for management, supervisory, operator, or maintenance training; Lack of any measurements to actively track the success of the maintenance department in maintaining the facility; The PM work orders reviewed were weak in terms of description, settings, and tolerances. ACTIONS: Conducted a Maintenance Best Practices Workshop for production and maintenance personnel. Cleaned up the MP2 CMMS that is being used by the maintenance department. Eliminated all obsolete work orders and then prioritized and estimated labor hours for all of the remaining work orders. Developed work flow diagrams that detail the entire planned maintenance process that we are implementing at the facility. Analyzed existing PM tasks and developed new PM procedures with specific tolerances and specifications for the critical equipment in the pilot area. Transferred this information into the MP2 system. Developed and defined key measurements used to track the progress of a proactive maintenance group. RESULTS: The majority of the production and maintenance staff completed the Maintenance Best Practices Workshop and were educated in all aspects of planned maintenance. The facility has a fully functioning CMMS that can be used to plan and schedule maintenance activities. The entire maintenance process has been documented using work flow diagrams. These diagrams can be used for training maintenance and production personnel. Updated PM procedures with specific tolerances for the pilot project area. Key measurements are now in place to track the progress of the maintenance group. |
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