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Scheduled
Work
Pre-shift
Validation
PdM Route
PdM Route
PdM Route
1300: XYZ-123d
1400: Urgent WO
PdM Route
1500: Work
Closeout
Available for EM
Callout if required
End of Shift
Conduct
Baseline
Take Readings
Overnight Repairs
No Defect Detected
Not Required
AC Induction
Motor Replaced
No Defect Detected
Defect Detected
No Defect Detected
Defect Detected
Vendor Called
Not Required
Yes
Not Required
Use Maint
Techs WO
Number for
Emergency
Yes
Yes for Oil
Analysis
New Gearbox
Installed by
Construction
Defect Detected
No Defect
Detected;
Baseline Taken;
Oil Analysis Sent
Out
Write Work
Request
Early defect identification affords the ability to schedule maintenance work during
the windows of opportunity that operations/productions offers us, therefore
creating the ability to run as much production as possible without an upset.
Q: What is a PdM Technician unable to provide to a Proactive
Organization?
A: A PdM Technician is unable to estimate when the failure will occur.
The focus of a PdM Technician is detection of defects that are random in nature.
To attempt to trend the propagation of a defect and forecast the actual time of
functional failure is a difficult proposition, as well as a very poor use of the
Technicians time. The defect will never be cheaper to address than directly
before failure, and the PdM work execution processes must be utilized to
address the timing of repairs as opposed to the PdM team. This one issue
causes more pain to an organization than any other, management always wants
to know: how much longer will it run? To this question, the only appropriate
answer is: how much risk are you willing to accept?
Sometimes, people lose confidence in PdM technologies. Listed below are some
common arguments:
Predictive Maintenance is not a true term.
This has some truth to it. Condition Monitoring is the true definition of PdM
because we are measuring the condition of specific failure modes at a
specified time. It may be 30-90 days because a reading is taken again.
If you really want to know what the most effective method for addressing
failure modes is, you must begin by determining what the most dominant
failure pattern is at your organization.
Less than 2% of organizations can identify a failure pattern statistically
because they do not have the data from their maintenance software to
support a decision. As it turns out, identifying the dominant failure pattern
is useless anyway. A study conducted in the 1960s by Nowlan and Heap
proved that the majority of failures are random.
As a PdM Technician, you know you are still in reactive maintenance mode
when:
An organization is only using Vibration Analysis and Infrared technologies.
Therefore, Technicians can only identify potential failures on specific
failure modes addressed by the two technologies. What about the failure
modes that can only be addressed by Ultrasound, UT, MCA, etc?
A Technician makes a repair after a defect, but the equipment is not
inspected to ensure it is defect free after the repair. For example, if a
loose electrical connection was repaired after an outage and Infrared is
not employed to confirm the defect has been fixed, how do you know that
the repair has been properly made?
Infrared technology is not employed for low voltage applications, only high
voltage.
Your maintenance technicians do not use repeatable effective work
procedures.
Your main source of failure mode identification is when something fails.