Critical to the success of a maintenance plan are the metrics used to track its progress. The improper analysis and work may result from poor data.
Good data can be collected with the use of well-written data gathering processes. However, plants typically fail to recognise the need of well-written procedures for most jobs, including data collecting.
This article offers advice on what makes for good procedures and how to draught generic upkeep checklists.
A documented standard, a standard maintenance process is a step-by-step guide for carrying out a maintenance activity.
All routine maintenance activities, whether performed by skilled workers, contractors, or operators, should be accounted for in SMPs.
In contrast to regular maintenance, preventative maintenance (PM) is performed before problems arise. False. SMP work includes PMs.
The health of your equipment, the security of your workers, and the efficacy of your factory all depend on having an SMP, or Standard Maintenance Procedure, in place. The guidelines for upkeep are documented in an SMP. There is a lot to think about while writing SMPs for the poultry processing sector. The Fundamentals: Preventative Maintenance is summarised below.
Maintenance operations can be performed more safely, efficiently, and effectively with the help of SMPs because they optimise and standardise these activities.
Advice on Effective Routine Maintenance
Tool, Part, Supply, and Expert Lists
Your SMPs should have a comprehensive stock of all the parts, equipment, and materials needed to do any given activity. It needs to be as detailed as possible, down to the exact quantities and quality levels of nuts, so that if something goes wrong, no one is at a loss for an explanation.
Specify whether or not other people, beyond the maintenance worker, must be present. Do you need to bring in outside help, such as a company or consultant, a manufacturing rep, or another worker?
Be Sure to Include the Boring Stuff
All the most common preventative maintenance procedures for your facility should be detailed in your SMP. The following are examples of possible responsibilities:
- Sufficient grease for bearings
- Transmission gearbox oil
- Adjusting the tension on the drive belt
- Adjustments, installation of bearings
- To change the drive chain
- Installation and repair of hydraulic hoses
The most experienced members of your maintenance staff are your finest resource when figuring out how to complete duties consistently. An inexperienced worker should be able to follow your standard operating procedure (SOP) without further instruction.
Consider Health and Safety Issues
The inclusion of safety considerations is crucial for an SMP. When determining the safest way to complete a task, it is essential to have all the necessary equipment and to have a thorough understanding of what needs to be done. A few examples of such items are:
Essential PPE for the job:
- Every potential health and environmental risk that could arise on the job
- A comprehensive set of instructions for carrying out the endeavour
- Detailed information about what is needed to perform the task
Warning should be used to prevent harm to people, whereas Caution should be used to prevent damage to property. The correct use of these words can alert the technician to important safety issues while preventing misunderstandings.
Standard maintenance procedures should be clearly documented and detailed enough to be followed effectively by qualified professionals who have never conducted the task before. Consistent SMPs assist eliminate the potential for error by reducing procedural variation.
Some items that should be maintained consistently:
- The names of tools shouldn't be altered from one procedure to the next.
- If at all possible, start each phase with a verb.
- Quantitative values should be entered by the worker (qualitative instructions give room for interpretation and may force a technician to rely on guesswork)
Toss in Some Pictures
Particularly for more extensive projects, visuals are a crucial aspect of effective SMPs. Including visual aids like photos, drawings, diagrams, and graphics in your SMP is a great way to further describe the tasks that need to be taken. In most cases, the tasks associated with maintenance are complex and hard to visualise. Getting things done faster can save your business a lot of money.
Educate Your Employees on SMPs
To ensure that maintenance technicians are performing their responsibilities according to the SMP, it is necessary for everyone to undergo training and complete tasks while being inspected by a supervisor. Every member of the maintenance team needs to be put through rigors training and testing to ensure they are competent in their roles.
Make Efforts to Enhance Your SMP
Your group will always be on the lookout for better ways to complete projects. Maintain an up-to-date SMP by recording new developments and incorporating them into existing sections. If you don't update your SMP regularly, it will quickly become obsolete.
Details Of Procedure
- The maintenance department plans preventative maintenance on machines on a regular basis based on usage patterns and past experience.
- Work on upkeep is carried out in accordance with the maintenance plan.
- Production (PROD) is responsible for carrying out routine maintenance tasks such as inspecting the machinery and replenishing oil and grease as needed.
- The maintenance department is responsible for implementing all predetermined maintenance schedules and other plans.
- And data are kept in the appropriate machine file.
- When a problem arises, the appropriate steps are taken to fix it, and a log of those steps is kept. The machine malfunction is reviewed by the maintenance manager, who then assigns a "Minor" or "Major" classification and keeps track of the number of hours the machine was out of commision, the number of spare parts used, and an estimated cost to replace or repair the broken parts.
- All significant machine breakdowns must have a root cause analysis and corrective/preventive action record kept, with the breakdown specifics, the success of the remedy done, and any preventive action taken noted.
Machine failures attributable to normal wear and tear on the repaired/corrected components will be categorised as "Minor," but recurrences of "Minor" will be elevated to "Major."
- Machine A file for each machine should be kept that includes information such the machine's model, capacity, location, and list of replacement parts.
- The goal of the Maintenance Manager's procurement and stocking of critical spare parts is to ensure maintenance with least downtime. Inventory of both essential components and existing supplies is recorded.
- A label providing information such as the name of the item, its intended use or application, and the date it was received must be placed on all consumable parts and accessories.Dissection 6.10
- All production machinery's breakdown report hours must be evaluated on a regular basis.
- Draw dies, rolls, and edge rollers used in production are checked for appropriate functioning as part of their routine maintenance (6.11). Both and are used to keep track of data.
- Oil spills, vibrations, emissions, and noise levels in the workplace are all matters that the maintenance team should monitor and keep track of.
Reasons for Using Procedural Maintenance
Just picture a business that has eliminated all lost-time accidents, is improving its OEE, and has a strategy to address the shortage of skilled workers. These locations already exist and are kept up with regular procedures.
All work performed falls under the purview of this type of upkeep. There is a sequence to breakdown, corrective, and preventative maintenance.
Excellence in operations is the result of well-defined processes and carefully monitored variations, not only of diligent employees (or not doing).
All potential sources of error in data collection, repairs, calibration, and commissioning are removed by using a procedure-based maintenance approach. Mistakes made by employees can be minimised with procedure-based maintenance.
Organizations can achieve three important goals if they standardise how they do things:
- Create a resource collection to help you cope with the impending skills gap.
- Recognize sources of variation and take steps to mitigate it so that your efforts provide predictable results.
- Reduce the possibility of making a mistake while performing maintenance.
The execution of procedures requires meticulous forethought. Without this methodical strategy, implementing the procedures won't work. It's important to have the processes well-organized so that they can be discovered quickly.
They need to be worded such that even people whose first language is not English can understand them and the task at hand is clear. Staff members must begin using them, with their comments being recorded and integrated into future revisions.
Procedures' Critical Role
Two common maintenance problems are solved by adopting a procedure-based approach. When numerous skilled workers take on a task, the margin for error decreases. Think about your choices for rebuilding the pump.
When taking anything apart, do you use a torch and hammer, or do you use actual tools? The environment, whether it be a cleanroom or a dirty shop, can have an effect on the quality of the finished product. Inspecting components: the rebuilder's way or the industry norm?
Is there an inspection procedure to determine which components need replacing, or is there a standard list? Thread-locking components are used for reassembly. Do approvals depend on experience or technical requirements? Can you rely on a torque wrench, or are you more of a rebuilder?
If you polled a group of skilled workers on how they go about reassembling and testing a pump, you'd get a wide range of responses. Such diversity makes pinpointing the root cause of an early failure or poor performance in a rebuilt pump challenging. By codifying best practises developed through staff experience, businesses can ensure a constant, reliable process with no room for error.
Formulating Routine Maintenance Procedures
When crafting an SMP, one must constantly weigh the pros and cons of either including too little or too much information. More time and effort spent developing the SMP means less time and effort spent on the task itself.
It is important to remember that no SMP, no matter how thorough, can be 100% accurate. Unsatisfactory or even disastrous results from the task at hand could result from insufficient attention to detail.
What, then, is an adequate amount of detail to include in the SMP? Even if the person performing the work has never done it before, they will be able to follow detailed instructions and complete the task successfully if they are experienced craftspeople (or operators educated in maintenance skills applicable to the task).
Who Should Create Guidelines for Routine Upkeep?
- A member of staff who has received formal instruction in SMP writing and is familiar with the company's established protocol for creating SMPs. (There really ought to be a method for writing a method.)
- A person is aware of the potential risks to herself and the environment.
- The expert who will be employing the SMPs in their work should be consulted by the writer. If the person doing the task writes the first draught, the SMP users are more likely to support the proposal. The likelihood of someone using anything they had a hand in creating is substantially higher than the likelihood that they would utilise something created without their contribution.
When it Comes to Routine Maintenance, What Are The Guidelines for Documenting Them?
- In written forms of communication, the onus is on the author, not the recipient. It's all about the customer service.
- Until the initial draught has been edited and tested, it cannot be released to the public.
- Make use of bullet points and avoid paragraphs (one item per step).
- Use concise, clear language.
- Please enumerate the actions in the correct order. There ought to be a logical progression to the process.
- You should use checklists wherever possible.
- Quantitative values entered by the worker are superior to simple checkboxes.
- Given the nature of the process, the text is written at an elementary reading level (about the fourth or fifth grade level) as much as possible. It is presumed that you have a level of reading ability appropriate to the requirements of the work itself.
- Whenever visuals would help explain anything, use them. The saying "a picture is worth a thousand words" is very true.
- Avoid jargon and repetition. There should be no renaming of tools or other pieces of kit from one procedure to the next.
- If at all possible, start each stage with a verb. Take Step 13: get rid of the coupling guard as an example.
- If there are too many stages involved in a job, divide it into subsections like "Remove Motor" and "Remove Gear Unit."
When Writing, Keep Safety in Mind.
- Even though potential dangers are outlined at the outset of an SMP, additional cautions should be provided prior to each potentially dangerous step.
- Make use of the term "Warning" to prevent injury to people, and the word "Caution" to prevent damage to machinery. One such example is the "Warning!" at the end of Step 23. Take out the line carrying the hot slurry.
The Effects of Procedures on Trustworthiness
Improved safety, dependability, start-up failures, average time to repair, and organizational learning are all outcomes of implementing procedure-based maintenance.
Tasks with known dangers will be safer. Because of this, steps to lessen danger are made possible. If something goes wrong, you can use these policies to mitigate any potential damage.
Reliability improves when work is routinely carried out in accordance with established technical standards. There will be fewer mishaps as a result. Failures can have their causes identified through analysis because of the repeatability of operations and activities.
All bolts will be correctly tightened, the region will be inspected, and any foreign items will be removed, reducing the number of start-up failures.
With a standard operating procedure in place and the necessary data at hand, the average time to repair can be cut significantly.
Using a procedure-based approach to maintenance aids with information organisation. Using this method, senior artisans can impart their wisdom to their junior counterparts regarding certain processes.
Implementing Policies and Procedures
It might be challenging to bring about the necessary cultural shift in an organisation to fully embrace procedure-based maintenance. In the future, there will be shifts in the maintenance department at every level. Artisans may no longer rely solely on their gut instincts but must instead adhere to established protocols and detailed guidelines.
Maintenance managers prioritise following and improving upon established protocols. Planners are more committed than ever to implementing new practises.
Recognizing the need for change, desiring to participate and support it, knowing how to change, putting in place necessary skills and behaviours, and reinforcing the change are all components of each stage of the framework.
The use of frameworks aids in recognising resistance to the change, addressing that resistance, explaining the benefits of the change to employees, and supplying them with the necessary information and training to implement the change successfully. Adoption and long-term sustainability of a change improve with more time spent on preparation and management.
Safety, dependability, and productivity are all enhanced by maintenance procedures. Before introducing procedure-based maintenance, a company must choose who will create the procedures, to what quality they will be prepared, and how the employees will be trained.
Applying Recognized Methods of Upkeep
The challenge is not in making effective SMPs, but in getting people to use them. While many businesses invest much in the creation of SMPs, the employee who actually does the work rarely if ever sees the finished product.
In these situations, SMPs serve simply as evidence of existence for auditors. By making an effort and receiving proper training, SMPs can contribute significantly to their employers' bottom lines. To encourage the widespread adoption of SMPs, it is necessary to make them both obligatory and convenient to obtain. Fasten to the machine, the operator's station, or the work instructions.
This article is useful for creating solid standard operating procedures (SOPs). Proper procedures are crucial to the achievement of reliable results.
FAQs About Property Maintenance
To keep a property completely functional and working at peak efficiency, it is necessary to perform regular maintenance, both proactive and reactive. There is a broad spectrum of tasks and demands that fall under the umbrella of property maintenance.
When it comes to taking care of the property, both the renter and the landlord or property management have certain responsibilities. The landlord or property manager is liable for making sure the rental unit is habitable.
In most states, a landlord is required to make sure a rental property is in a habitable condition when the tenant first moves in. Also, once the tenant moves in, a landlord is required to make repairs and conduct maintenance to keep the rental property in a habitable condition.
Basically, the property maintenance firm takes care of the cleaning, gardening, and seasonal repairs, as well as the ad hoc repairs, such as changing out doors, mending locks, and repairing roof leaks. The Property Manager and the maintenance company normally have a schedule of days and times when the company will be on-site.
Building maintenance includes cleaning common areas, removing trash regularly, and repairing items that are broken. It can involve inspecting, repairing, and maintaining electrical systems, heating and air conditioning systems, and other utility services.
A SMP is a detailed instruction manual for performing a particular type of upkeep. Having a solid SMP in place is crucial to the well-being of your machinery, the safety of your employees, and the productivity of your manufacturing facility. Writing strategic management plans (SMPs) for the poultry processing industry requires careful consideration of many factors. Be sure to specify if anyone else besides the maintenance worker is required to be present. When trying to figure out how to reliably complete tasks, your most seasoned maintenance workers are your best resource. The documentation of standard maintenance procedures should be thorough enough to be effectively followed by trained experts.
- Critical to the success of a maintenance plan are the metrics used to track its progress.
- Good data can be collected with the use of well-written data gathering processes.
- However, plants typically fail to recognise the need of well-written procedures for most jobs, including data collecting.
- A documented standard, a standard maintenance process is a step-by-step guide for carrying out a maintenance activity.
- All routine maintenance activities, whether performed by skilled workers, contractors, or operators, should be accounted for in SMPs.
- In contrast to regular maintenance, preventative maintenance (PM) is performed before problems arise.
- The health of your equipment, the security of your workers, and the efficacy of your factory all depend on having an SMP, or Standard Maintenance Procedure, in place.
- The guidelines for upkeep are documented in an SMP.
- There is a lot to think about while writing SMPs for the poultry processing sector.
- Your SMPs should have a comprehensive stock of all the parts, equipment, and materials needed to do any given activity.
- Be Sure to Include the Boring Stuff All the most common preventative maintenance procedures for your facility should be detailed in your SMP.
- Consider Health and Safety Issues The inclusion of safety considerations is crucial for an SMP.