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For Supervisors, Planners, Vibration Analysts, & other roles that lead the work process.
precision maintenance boot camp

Objective

The Reliability/Precision Maintenance Boot Camp is designed to accelerate the essential knowledge and skills necessary for reliability engineers and other essential roles that are expected to lead to reliability improvement. In many cases, these individuals have never been formally introduced to these strategies, processes, and tactics, yet they are expected to be the “go to” source for solving difficult problems and achieving improvements.

Background

Real data from over 200 facilities show that maintenance-induced defects overwhelmingly contribute to stalled improvement efforts to gain back control. The data indicates that 25% are due to common assembly errors, 25% from imbalance and poorly balanced specs, 25% from poor alignment, inadequate alignment of specs and leadership expectations, and 25% common lubrication mistakes. The plain truth is, our craftsmen, entrusted to maintain millions of dollars of production equipment, have never been taught the skills necessary to “Do it once – Do it right.” Armed with these vital skills, craftsmen and front-line leadership can begin eliminating unscheduled downtime, recapture lost opportunities, and drive the production and profits in the right direction – up.

Boot Camp Topics

10-Steps to Precision Maintenance: Strategies, Processes, and Tactics

  1. Awareness of business issues and trends
    1. The loss of skilled craft-mechanics due to retirement and how the rebuilding of these skills-sets must be addressed.
    2. The enormous challenge to increase production and reduce manufacturing costs.
    3. What precision maintenance is and how the application of these skill-sets are vital in meeting these challenges.
    4. Participants will be given a list of “Field Observations” to take back to their job site and determine if work is being performed correctly.
  2. Precision Maintenance Skills Assessment
    1. A review of how the Skills Assessment provides an objective measurement of craft-mechanic knowledge and understanding of precision maintenance skills whereby a sensible, defensible, skills development plan can be formulated.
  3. Sr. Management Sponsorship
    1. A review of the critical importance of site leadership’s understanding of the strategic connection between reactive, unscheduled downtime due to improper work, and conversely, how applied precision skills are significant to the performance improvement of equipment.
    2. All contributing roles must see management’s commitment to follow through and foster, building a reliability culture that runs through every fiber of the site.
  4. Roles, Responsibilities, and Processes
    1. Maintenance management, front-line supervisors, planners, vibration analysts, and all significant roles must understand how they each contribute to moving this improvement work forward, including:
      1. Job Plans, Field Documentation, planning and scheduling precision work, and setting the expectation that the goal is to “Do it once, Do it right,” from here on in.
  5. Training Implementation
    1. Following the Skills Development Training Plan (derived from the Precision Maintenance Skills Assessment), participants will:
    2. Learn the principles behind each method through the instruction of the curriculum (Course books, PPT’s, and static demonstrators).
    3. Then, they will perform numerous hands-on, step-by-step exercises on simulators that replicate real-world, operating equipment.
    4. These simulators are specifically engineered to enable instructors to impart assembly errors and many common mistakes.
    5. Participants are then systematically taught to identify and eliminate each one.
  6. Application of Skills
    1. With their new skills, knowledge, tools, and work orders, craft-mechanics can immediately begin to convert poorly operating, high risk of failure machines into improved, reliable machines – operating as intended with increased resistance-to-failure.
    2. This is where the craft-mechanics can deliver real value. Precision assembly, installation, and rebuild occurs throughout the operating lifecycle of site equipment, not just at commissioning. By raising the “Quality Standard of Work”, defects can be eliminated by not imparting them in the first place.
    3. We’ll review the DIPF curve (UPTIME ELEMENTS™) and show how all the precision elements are the essential enablers for equipment to operate on top of the curve consistently longer – MTBF.
  7. Measuring Results – KPI’s
    1. Number of “Improvement Work Orders” completed monthly
    2. Reduced Energy Consumption
    3. Reduced Vibration
    4. MTBF and how it powers achievement of all good things financially
    5. Increased Incremental Production
    6. Reduced Manufacturing Costs
  8. Progress Review and Mentorship
    1. Conducting a progress review can provide maintenance management with valuable, continuous improvement recommendations and highlights the areas where success is being achieved.
    2. Front-line supervisors establish a process to review the documentation of each precision maintenance job and will be able to recognize the quality of work and if additional on-site mentoring is needed to re-enforce the continuous improvement of each craftsman.
  9. New Hires
    1. Management will recognize that new hires typically lack the necessary skills to meet the new quality of work standard set by the existing team. New hires can be assessed, similar to Step 2, to determine their current knowledge and the specific training they will need to raise their skill-sets to the expected level.
  10. Achieving Sustainability
    1. All the previous steps are the proven best practices and essential in achieving a standardized reliability/Precision Maintenance process, the highest level of success, and a sharp focus on continuous improvement.

A Successful Precision Maintenance Implementation Case History

  • How this site applied the essential steps and:
  • Successfully increased MTBF by 400%,
  • Reduced maintenance cost,
  • Increased production and,
  • Sustained results.

Hands-On Exercises

  • These hands-on exercises will be an accelerated pace for both Skill 1: Assembly, Installation, Rebuild, and Skills 2: Precision Bearing Installation, Assembly, and Lubrication courses. In this way, each participant can experience for themselves the key elements of a precision assembly, installation, and rebuild skills necessary to enable equipment to run as intended – reliably.
  • They’ll see the myriad of common assembly errors and mistakes made every day by craft-mechanics and supervisors that seriously reduces the equipment’s resistance to failure. They will learn why it’s important to pay attention to all the little things that, when ignored, increase unproductive load, and are the primary root cause of machinery failures.
  • They will learn how to easily double or triple rotating equipment life by making vibration much lower through the elimination of common assembly errors and adherence to precision assembly, installation, rebuild, and maintenance standards which we will show how it’s achieved with little or no extra downtime.
  • Performing the same work as the craftsman, with their own hands and working with our simulators, they will participate in converting a poor, high risk of failure machine into an improved, reliable machine.
  • An essential role for these participants is to lead and cause improvement work to go forward:
    • Participants will see the value and the investment you’re making.
    • The Boot Camp class provides the excitement of discovery.
    • Exercises are hands-on and real-world applicable.
    • Equipment performance changes are demonstrated and proven in class.
    • Your Reliability Engineers will leave the Boot Camp with the right experiences.