The 7 Habits of a Highly Effective Maintenance Organization

The 7 Habits of a Highly Effective Maintenance Organization

"The 7 Habits of a Highly Effective Maintenance Organization" directly relates to the teachings of Doctor Steven Covey's landmark book, The 7 Habits of Highly Effective People. This whitepaper relates the 7 Habits to the Maintenance field and optimizing your maintenance organization. The 7 habits are built on fundamental principles which helps ensure their implementation is successful. This white paper is intended to encourage Maintenance organizations to internalize these habits in order to develop an organization that is "Proactive" rather than "Reactive." Proactive organizations have less stress, and less cost internally, and are viewed as better suppliers of services by their customers, than reactive organizations

Maintenance 101

You’ve just been named Maintenance Manager of a large manufacturing plant. You have the responsibility of maintaining the plant equipment at a high level of reliability within a severely constrained budget. How in the world do you get your arms around this beast we call Maintenance and get it under control?

The good news is that there is a wealth of information in books, magazine articles, internet articles, and conference proceedings concerning the subject of Maintenance Management. It’s also the bad news, because there is so much out there that it’s overwhelming. It really doesn’t tell you where to start. Tthis white paper will explore ten of the most basic concepts that every maintenance manager must know to put into practice. These will provide a springboard to more advanced concepts that will provide increasing value to your organization. 

Maintenance 201

The Maintenance Management 101 white paper explored ten of the most fundamental concepts that newly appointed Maintenance Managers need to understand in order to build a proactive work culture. This white paper builds on those points by discussing ten additional concepts that both reinforce those foundational elements and provide guidance for ingraining them into your organization. Many of these concepts address managerial tips and techniques that are not always addressed in company-sponsored management training programs, but are essential for building an organization that contains the requisite level of discipline for creating a world-class reliability program. 

Elevating Maintenance and Reliability Practices The Financial Business Case

The presentation will address:

The current state of maintenance and reliability, the level of awareness among business executives of financial business performance that can be achieved with top level reliability practices, and “what good looks like” in the few successful companies which have reached top quartile performance and enjoyed significant benefits.

Performance yet to achieve - even by the top performers.

Statistics showing the potential benefits in United States industrial companies and how that might extrapolate out to companies world-wide What the business case might be at your corporation. 

Turning Corporate Asset Management into real earnings per share

This white paper gives the non-financial professional the basic tools to build a business case for reliability that financial professionals will understand and accept.

While Corporate Asset Management (CAM) has been a hot topic amongst global companies for the past decade, the demands of the transformational requirements (culturally, technologically, procedurally and philosophically), compounded with the time to achieve, often mask or even prohibit the visibility of bottom line financial benefits. The question becomes, “How do we implement a Corporate Asset Management strategy so that real business value can be seen at each phase of the transformation?” This white paper focuses on the business tools necessary to communicate the business value to corporate decision makers. 

Master Records are Not Optional Get the Detail Work Behind You

Don't miss this opportunity to learn how populating your CMMS/EAM with correct master records will allow the transactional data to lend itself to valid and useful analysis that bolsters critical thinking and identifies the vital opportunities that are worthy of pursuit. In this iPresentation, Todd White, CMRP, illustrates the importance of quality foundational data to Maintenance and Engineering who have to own the processes and be responsible for the availability and integrity of the master records and transactional data to drive and support business decisions. 

Data is a Universal Issue

This white paper will discuss the value of having high integrity data within your systems. The primary discussion points are:

• Data Integrity Is A Universal Issue

o How Did We Get There?

o Today’s Data Issues

• Data Integrity Affects Business Performance

• Searching for Data Is Costly

• Enhancing Data Integrity Is An Opportunity

Materials Management - It’s Half the Battle

In many maintenance organizations, 50% of the annual maintenance budget is spent on material and spare parts … not to mention that a significant amount of time is “spent” acquiring these spare parts. This expenditure is often a significant percentage of a plant’s total operating costs. Strangely enough, many of these organizations have almost no control of their materials. One part of the organization feels there is too much inventory and the other part thinks there isn’t enough. Why do these problems exist? What can be done about them? How do you match the demand for parts with the supply?

This presentation will take a humorous but serious look at the issues (good and bad) associated with material management for a maintenance organization. We will uncover the hidden inefficiencies of poor material management that occur thousands of time a day and their costs. These inefficiencies cumulatively add up to incredible losses to our businesses. We will also present ideas and solutions to improve these poor practices. We will make the business case for implementing enhanced materials management processes, practices, tools and techniques that are fully integrated into the work management processes.  

Readiness for RCM – Tuning Your CMMS to Support Reliability Based Maintenance

Most providers of Reliability Services emphasize the importance of utilizing your Computerized Maintenance Management System (CMMS) or Enterprise Asset Management system as a key element of an overall reliability strategy. This is because a robust and revitalized CMMS or EAM provides both short-term and long-term benefits to the organization. Some of the long-term benefits impact the organizations ability to perform more robust Reliability Centered Maintenance (RCM) Analysis and Root Cause Failure Analysis (RCFA). An additional long-term benefit of a revitalized CMMS/EAM is to provide better metrics for evaluating all aspects of the health of your reliability improvement initiative. 

RCM Process Reduces Maintenance Spending and Increases Production Output

RCM analysis is a powerful tool to change attitudes and practices for both maintenance and operations personnel. This case study examines how Purac America successfully used RCM to improve high cost, underperforming equipment. Maintenance spend fell from 7% of RAV to 4% of RAV and production increased from 50% to 133% of rated nameplate capacity.

Many maintenance organizations do not realize how they impact regulatory compliance. However, much of what Maintenance does has a direct affect on federal regulations and can cost the company millions if their actions cause an out of compliance situation.  

Applying the Best Maintenance Strategies to Your Assets

Many companies have implemented Reliability initiatives geared toward optimizing the maintenance function at their plants. Some are successful; however, most will admit they did not realize the expected benefits. While there are many approaches to successfully implementing a Reliability program, this paper will discuss a proven model for improving a company’s Reliability-based maintenance program through maintenance task optimization focused on failure elimination. 

Can Reliability Based Asset Care Improve a Food Manufacturer’s Bottom-line

Improving enterprise wide asset reliability is one of the most effective ways to improve a food manufacturer's bottom line. In order to obtain the significant business benefits offered by reliability improvement initiatives, today's food manufacturing managers, from the executive suite to the plant floor, all need to be well versed in the factors affecting asset reliability. Without top-to-bottom awareness of asset reliability fundamentals, business performance improvements will continue to be incremental and non-transformational. With the awareness provide by this white paper, food manufacturing managers can begin to enhance return on assets (ROA), accelerate results, and make the competition take notice. 

Cost Effective and Compliant Maintenance

The understanding of this within maintenance organizations varies from complete ignorance to maintenance by decree. The latter is a maintenance strategy which is defined by fear of the regulatory bodies and paralysis when trying to adopt proactive maintenance strategies. On both ends of the spectrum, reactive maintenance is the prevailing strategy and change to a true proactive reliability program is very difficult.