What is Precision Maintenance?
As the name implies – precision is the quality
of being accurate – is the level of exactness that is normally close to the
desired standard. Similarly, precision maintenance involves maintenance
activities that are performed thoroughly, accurately, and precisely as per
defined standards in identical and repeatable ways which are also consistent
with the documented maintenance procedures.
A
strategic approach to maintenance where even small details are focused and ensures
that operational reliability is maintained by strictly adhering to maintenance
procedures and manuals. Precision Maintenance is a critical concept in total production maintenance that requires discipline with diligence in many
maintenance efforts – without precision one cannot achieve the desired level of
performance. Precision maintenance promotes quality assurance by eliminating
different kind of variances in maintenance processes and techniques that causes
instability in production (and that is possible with the help of SOPs and
maintenance checklists).
The need for precision in maintenance is not
new in the maintenance field but this concept was first derived in the ‘80s and
endorsed by maintenance specialists that only rigorous compliance with
equipment or component specifications can result in the highest standard of
reliability. Omission of minor but essential details such as – “a little
misalignment”, “over lubrications”, and “overlooking unusual bearing noise” –
are the maintenance-induced defects that stall improvement efforts and reduce
equipment life.
Benefits of Having Precision Maintenance:
The rewards of precision maintenance are numerous
and that includes not only a reduced downtime of equipment but impacts
positively on other areas of sustainability and reliability. Some of them are
given below:
1- Precision
maintenance creates a positive maintenance culture – instills a sense of
ownership and job satisfaction through the inclusion of precise operating and
maintenance equipment procedures.
2- It increases an
equipment lifespan by noticing and maintaining all parts of the machine or
component – no matter how small it is – attending to these minor abnormalities saves
the organization from the hassle of many functional failures that can pop up later
in life.
3- Reducing
equipment downtime is another major benefit that comes with implementing a precision
maintenance program that ensures all parts of equipment undergo preventive or
predictive maintenance through which many incipient and hidden defects get
cleared thereby improving machine reliability. Since downtimes are expensive so
companies save a lot with this program.
4- The company’s
maintenance workforce is skilled and equipment-trained – which increases the company’s
worth and improves asset management.
5- Precision
maintenance always underscores the importance of continuously improving
maintenance documents which empower the maintenance team and ultimately paves
the way to the highest efficiency in production and productivity.
6- Precision
maintenance also reduces overall maintenance costs by effectively utilizing
maintenance resources and minimizing the need for unplanned equipment downtime
because of the comprehensive equipment maintenance checklist under the umbrella
of a total productive and precision maintenance program whose main objective is
to look out for those hidden failures which can cause cascading failures.
7- Another major
benefit of following a precision maintenance program at your plant that is it helps
in root cause analysis as each part is thoroughly inspected during the maintenance
or failure finding process which also becomes a part of root cause analysis.
8- A rigorous implementation
of precision maintenance helps the workforce to predict equipment failure
before it actually occurs – it also improves the document of equipment FMEA
(Failure Mode and Effect Analysis).
9- Lack of
precision may lead to fatal accidents or hazardous leakages – this can happen when
a technician ignores an abnormal vibrational sound, improper torquing, use of
improper tools, etc. This safety hazard can only be minimized or mitigated
through the means of accuracy in maintenance – thence precision maintenance is
important.
Maintenance Lacking Precision:
There are a number of indications that
precision in PM maintenance is not being followed:
1- Consistently
shorter PM times are one indication that precision in maintenance is missing.
2- The checklist
of preventive maintenance is not properly followed and completed as specified
by its standard procedure.
3- Items from the checklist
are skipped.
4- Improper tools
are used for tightening.
5- There is no
inspection audit system.
6- Lack of skilled
and knowledgeable employees.
7- Overlooking
minor details like small abnormal sounds or vibrational noise.
8- Equipment
specifications and installation & maintenance documents are not accessible.
9- Missing
drawings and specifications
10- Modifications
are not updated.
11- Accuracy in
shaft alignment and imprecision in balancing rotating parts.
12- Root causes of
failures are not properly identified.
13- Lack of
supervision.
14- Feedback from
maintenance tasks is not properly recorded.
15- No Preventive
and Predictive maintenance plan.
Precision Maintenance Execution:
In order to get a consistent result, one must carry
out maintenance work with precision and that too regardless of the technician –
a difficult task though but ensuring the same procedure is the key to precise
maintenance. Precision Maintenance requires a cultural change in a facility – a
company-wide philosophy that stresses following the best practices and
equipment standards religiously by everyone – this cultural change is a vital
point in the execution of precision maintenance.
Apart from cultural change, there are some
basic tools that make the implementation of precision maintenance in an
organization possible.
Basic Skills
and Training:
Precision Maintenance is not possible without
skilled maintenance personnel. Technicians must have the necessary knowledge
and skills about the equipment installed at the plant – which is of utmost
important thing in pursuit of equipment reliability. Technical training over
the course of an employee’s tenure is mandatory due to the continuous inclusion
of complex equipment and the staff need to fill this gap by having basic
command of these technologies. Organizations can also take advantage of the
skill gap assessment to create a sensible skill-based training program for the
maintenance workforce and have them delivered in-house – repeatedly.
Training like basic precision maintenance
skills, understanding of measuring and adjusting torque, measuring vibrations,
application of adequate lubrication, knowing the equipment’s normal operating
temperature, and schematics reading, etc. are very important for the objective
of the company’s continued improvement as mastering these skills can avoid human-induced
errors and technician can be more aware, accurate and precise during
maintenance and installation process.
Documentation:
Precision maintenance can’t be implemented
without properly documented procedures and their availability to maintenance
personnel is important as well. Precision maintenance is all about a set of
precise maintenance procedures readily available to the workforce which are
detailed, unambiguous, and as per O&M specifications/standards (and refrain
from assumptions).
Calibrations:
Tools and testing equipment calibration are
equally important in the process of execution of precision maintenance.
Organizations need to ensure that all tools are calibrated before the date
expires.
Learning
Culture:
Everyone learns something new every single day but
what if all of us share our learning with our colleagues? Something remarkable
would happen in the process of continuous improvement. Along with extensive
classroom training, the one-point lesson is a remarkable way for maintenance technicians
and equipment operators to continually learn new details that help them improve
their precision maintenance practices.
One point lesson is about imparting one lesson
at a time – just every other day – rather than shoveling down the lump of
details in a single go.
Leadership
commitment:
Precision maintenance implementation requires full-fledged
support and sponsorship of senior leadership. It is important for managers to
refrain from applauding technicians for restoring a breakdown as it promotes
the culture of reactive maintenance in an organization. The role of leadership
in the process of seeking precision maintenance is to promote Proactive and
Predictive maintenance and approve the necessary resources that are required
for its effective implementation. It empowers people, builds confidence, and
encourages innovation which eventually improves service and performance.
Quality:
Make sure that the parts, components, tools,
and materials used in maintenance tasks are of high quality. Low-quality materials
may save you peanuts initially but it costs more in a long run.
Performance
Indicators:
Another way of achieving the best results out
of continuous improvement initiatives is the Plant’s Key Performance Indicators
– Maintenance cost, Mean Time Between Failure, Reduced overall vibration level,
etc.
Measuring performance indicators imbues
ownership of the plant among the team and also gives them a tangible threshold
to meet.
Audit System:
Maintenance procedures and PM results should be
regularly checked for faults. The advantage of auditing the maintenance plan and
procedures is to look out for any possible area of improvement as per plant or
equipment needs.
PM Plan:
Since the concept of precision maintenance is
built upon the existing Preventive and Predictive Maintenance program so the
organization must have a robust maintenance plan and asset management policy in
their place – the foundation of building a precision maintenance program.
Organized
Workplace.
Workplace organization is a great way to improve precision in maintenance and operation activities which are developed on 5S++ program + safety and security. The pyramid of the visually controlled workplaces is ideally a zero defect and zero abnormality workplace.
Conclusion:
Precision Maintenance may take years to achieve
but it enables organizations to get the most out of their maintenance program –
precisely the outcomes are a safer workplace, a knowledgeable workforce,
healthier equipment, and less maintenance cost.
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