MAINTENANCE CULTURE

@ MAMA CASS RESTAURANTS LIMITED

By Osagie Alfred

Definition of Terms
Maintenance is the sum total of actions taken to prevent a device, component or equipment from failing as well as the repair of normal equipment degradation experienced with the operation of the device to keep it in proper working order.

Culture in this context is a particular set of attitudes that characterizes a group of people

What is Maintenance?

Maintenance Perception
Maintenance is costly

OPERATIONS + MAINTENANCE = PRODUCTION

Therefore, facilities Maintenance Department should be given necessary attention given to Operations (Cafeteria, Jaydens etc).

Maintenance Perception (contd)

Until recently, maintenance has not always been considered a mainstream function. It has always been seen as a negligible sub-system of production and probably, a necessary and an unplanned overhead. Maintenances primary responsibility is equipment reliability. In the present climate of increased globalisation and the obligation to reduce production costs, the assets of a company capital, buildings and machinery, - are much more critical than ever before. Consequently, the importance of managing assets efficiently and effectively has become very germane to the bottom-line of organisations. business reality.

Maintenance Strategy Options

Planned: Preventive, Predictive, Reliability Centered etc

Unplanned: Corrective Maintenance

Maintenance Strategy Comparison

Maintenance Strategy Breakdown/ Corrective

Advantages No prior work required

Resources/ Disadvantages Technology Required Disruption of production, May need labor/parts injury or death at odd hours

Preventive

Work can be scheduled

Labor cost, may replace healthy components

Need to obtain labor/parts for repairs

Predictive

Impending failures Labor costs, costs for can be detected & detection equipment and work scheduled services

Vibration, IR analysis equipment or purchased services

Composition

Preventive Maintenance

Corrective Maintenance

MCRL Facilities Preservation

For Critical

For non-critical

Autonomous Maintenance.
PM orders carried out by the production workers. Known as user maintenance orders. They should be simple and graphically represented. Many inspection tasks should be carried out every day. Significant amount of notices that could be easily handled by the production worker. It takes more time to fill out the request order than to fix the problem Autonomous maintenance includes these small tasks and three daily preventive measures. Cleaning, lubricating and checking.

Safety Concerns

Safety is one of the most important restrictions.

Autonomous tasks apply only for simple repair operations. Repair or maintenance should never be performed if the knowledge required to fix the machine is high. 9/80

Autonomous Maintenance.
It can be very challenging to convince production workers about the importance of maintenance tasks. They do not consider their responsibility.

Safety Concerns

Safety is one of the most important restrictions.

Autonomous tasks apply only for simple repair operations. Repair or maintenance should never be performed if the knowledge required to fix the machine is high.

10/80

Autonomous maintenance
Autonomous maintenance implementation process has a specific methodology. These include

7 6 5 4 3 2 1

Autonomous Supervision Process Quality Assurance Autonomous Maintenance Standards Overall inspections Cleaning and Lubricating Standards Countermeasures to Sources of Contamination Initial cleaning

11/80

Human-Facilities Similarities

They both have life and life-span

They need regular check-ups They need replacement of parts.

Elements of Equipment Reliability

Appropriate specification and design practices Professional purchasing practices

Appropriate storage facilities

Precise installation methods Well defined and consistent start-up and commissioning procedure

Consistent operating practices

Proactive maintenance processes.

Reliability, just like safety, is EVERYONES responsibility

Elements of Equipment Reliability

Elements of Building Reliability

Buildings original design, size and facilities Quality of construction used in building

Finishes and equipment specified for installation

Affect

Property Operation & Maintenance (POM) related costs

The bath-tub curve

Basic Maintenance Actions

Never assume knowledge of any equipment/machine Switch off all electrical appliances when not in use (e.g. Laptop) Do a routine check on all your work equipment before settling into the days work. Report all potential hazard and fault. Be humble and willing to learn, every equipment, component etc is unique in its own way. Ask questions when in doubt, never assume you know what to do.

Report faults objectively and not be an alarmist. Dont cry wolf where there is none.
Do routine cleaning and check on all components. Develop a maintenance culture and see yourself as a stakeholder in the maintenance of the equipments under your custody.

A mal-functioning system is a hazardous system.

Situation Report
Equipment are used to run-down No due diligence check before equipment are purchased. Existing equipment have been inadequately maintained. Lack of a Comprehensive Facilities Management software. Lack of Condition Assessment tools e.g. Lack of up-to-date Asset Register

Establishing Maintenance Culture

1.
2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

An effective Job Order system

Replacement Policy Employees accept responsibility for
Observe, Check, Adjust, Clean and Notify

Well-trained personnel Adequate resources Proper application of the three maintenance strategies Continuous research and improvement. Due diligence check before equipment are purchased. Conduct annual comprehensive facilities audit. Purchase of a Comprehensive Facilities Management software. Continuously run an up-to-date Asset Register. equipment/system reliability