Details, Do we really need Them?

November 17, 2011

Often unrecognized, Planning is an invaluable tool in today’s maintenance toolbox. In many cases, the planning phase defaults to simply creating a work order with a statement such as “repair #3 boiler circulating pump which appears to have failed”. Now, most Technicians can pull some tools together, pick-up a bunch of parts and attempt to repair the asset. But in reality, this fuels the inefficiency fire and can’t be reused in the future.

Let us look at a different approach:

Consider the same problem statement rewritten as Repair # 3 circulating pump by replacing the outboard pump bearing. This bearing appears to be ready to fail according to the vibration analysis report (attached). Lockout the asset according to the lockout plan (attached). Replace the bearing in accordance with Acme Pump manual 2376 (attached), section 4, steps 4-1 through 4-21. Test the unit in accordance with section 2, steps 2-1 through 2-12. If testing is acceptable, place the unit back in service. Complete this Work Order with all materials utilized, hours taken to accomplish tasks and any additional details that would be helpful if this task is assigned again in the future. Now we have provided the precision steps necessary to execute a level of standard work via the OEM manual.

Together with the correct parts and a time estimate to complete, this approach will allow the Technician a better chance of successfully and efficiently completing the task and minimize the need for rework due to an improper repair. When the work is repetitive as many jobs are, use the same approach to create a reusable standard job plan. In some cases, the job plan serves as a checklist which is advantageous and includes the use of steps to accomplish the task as well as a means for documenting the work. Each checklist should have a space to check off each task as well as a signature block for the Technician and possibly the Supervisor to sign off for critical tasks.

Proper work instructions will not only allow the task to be completed properly, but also serves as a training tool for the future.

To answer the question “Details, Do we really need them?” Yes you do.

To learn more about Maintenance Planning, join us December 16 for Measuring the Central Hub - Planning and Scheduling Metrics.

Register today: https://www1.gotomeeting.com/register/124362920

Tip provided by: Dave Abecunas, Senior Consultant, People and Processes, Inc.