The Journey to World Class Maintenance

Presented by: Ricky Smith, CMRP February 2013

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A Proactive Reliability Process is a supply chain. If a step in the process is skipped, or performed at a substandard level, the process creates defects known as failures. The output of a healthy reliability process is optimal asset reliability at optimal cost. - Ron Thomas, former Reliability Director Dofasco Steel, Hamilton, ON

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A few questions which need to be answered!

How many companies achieved World Class Maintenance? How long does it to achieve World Class Maintenance? What are the benefits of World Class Maintenance? What are the attributes - World Class Maintenance Organization?

Managers who visited the plant have said they do not agree with Alumaxs approach to Maintenance however they cannot say it does not work - John Day PE

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Known Companies World Class Maintenance

Exxon - Baytown, Texas (Exxon-Mobil) Alumax Mt Holly (Alcoa Mt Holly) Goose Creek, SC Ford Motor Company Paris, France

Alcoa Mt Holly

Exxon-Mobil Baytown

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Time to Achieve World Class Maintenance

Not time dependent It is a journey not a program The journey never ends, the view just gets better

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World Class Maintenance How hard is it?

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Benefits of World Class Maintenance

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World Class Maintenance Attributes

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World Class Maintenance Attributes

Managements Vision
Begin operations with a planned maintenance system that could be developed into a total proactive system utilizing a Computerized System as an enabler Integrate all the plant business functions into one on-line common data base system available to all employees in their normal performance of duties. From a basic point of view there are two maintenance approaches.
One approach is reactive and the other is proactive The Proactive Approach was selected The goals of this approach
Continuous equipment performance to established specifications Maintain Capacity (Capacity Assurance) Continuous improvement

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Proactive Model World Class Maintenance

Breakdown

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World Class Maintenance Results

Wrench Time = 62.8%

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Maintenance Definition by John Day PE

To Maintain Keep, Preserve, Protect from Degradation Maintain Capacity

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World Class Maintenance Journey

The Journey never ends, sit back and enjoy the view

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Alcoa Mt Holly Where are they now?

Recently won the NAME Award People visit their plant and cannot believe what they see Hundreds of companies have visited their operation

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Questions/Comments?

WebEx Scheduled for Monday, Feb 4, 2013 Interested contact the email below: rsmith@gpallied.com
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