Page 26 - Intro Predictive Maintenance

Impact of Maintenance 17

The Difference. Other than the mission or intent of how predictive maintenance is
used in your plant, the real difference between the limited benefits of a traditional
predictive maintenance program and the maximum benefits that these technologies
could provide is the diagnostic logic used. In traditional predictive maintenance
applications, analysts typically receive between 5 and 15 days of formal instruction.
This training is always limited to the particular technique (e.g., vibration, ther-
mography) and excludes all other knowledge that might help them understand the true
operating condition of the machine, equipment, or system they are attempting to
analyze.

The obvious fallacy in this approach is that none of the predictive technologies can
be used as stand-alone tools to accurately evaluate the operating condition of critical
production systems. Therefore, analysts must use a variety of technologies to achieve
anything more than simple prevention of catastrophic failures. At a minimum, ana-
lysts should have a practical knowledge of machine design, operating dynamics, and
the use of at least the three major predictive technologies (i.e., vibration, thermogra-
phy, and tribology). Without this minimum knowledge, they cannot be expected to
provide accurate evaluations or cost-effective corrective actions.

In summary, there are two fundamental requirements of a truly successful predictive
maintenance program: (1) a mission that focuses the program on total-plant opti-
mization and (2) proper training for technicians and analysts. The mission or scope
of the program must be driven by life-cycle cost, maximum reliability, and best prac-
tices from all functional organizations within the plant. If the program is properly
structured, the second requirement is to give the personnel responsible for the program
the tools and skills required for proper execution.

1.2.3 It Takes More Than Effective Maintenance
Plant performance requirements are basically the same for both small and large plants.
Although some radical differences exist, the fundamental requirements are the same
for both. Before we explore the differences, we need to understand the fundamental
requirements in the following areas:

• Plant culture
• Sales and marketing
• Production
• Procurement
• Maintenance
• Information management
• Other plant functions

Plant Culture
The foremost requirement of world-class plant performance is a work environ-
ment that encourages and sustains optimum performance levels from the entire
workforce. This plant culture must start with senior management and be inherent