Welcome to CMRP Training At MAF Session 6

Chapter’s and Instructors Chapter Chapter Title Instructor Chapter 1 Introducing Best Practices John Pucheu Chapter 2 Culture and Leadership Mike Dawson Chapter 3 Understanding Maintenance Fred Harden Chapter 4 Work Management: Planning and Scheduling Tamora Houser Chapter 5 Materials, Parts, and Inventory Management Arlan Cochran Chapter 6 Measuring and Designing for Reliability and Maintainability Vic Silecky Chapter 7 The Role of Operations Joe Wiley Chapter 8A PM Optimization Chris Packwood Chapter 8B PM Optimization Ronnie Richard Chapter 9 Managing Performance Joe Costa Chapter 10 Workforce Management Cheryl Redmon Chapter 11 Maintenance & Reliability Analysis Tools Pat Campbell Chapter 12 Current Trends and Practices Bryon Walker

Society for Maintenance & Reliability Professionals Introduction SMRP Society for Maintenance & Reliability Professionals Introduction At MAF

About CMRP SMRP is a nonprofit professional society formed by practitioners, with a mission to serve leaders and advancing Reliability and Physical Asset Management. SMRP provides value for individual practitioners as well as companies practicing and sustaining Maintenance and Reliability (M&R) best practices. SMRP has nearly 3,800 members worldwide. MAF has 51 certified members to date 25 people took the exam on October 27th and 17 passed CMRP is the certification arm of SMRP and has approximately 3,000 members.

SMRP’s Body of Knowledge (BOK) – 5 Pillars SMRP Body of Knowledge 1.0 Business & Management 2.0 Manufacturing Process Reliability 3.0 Equipment Reliability 4.0 People Skills 5.0 Work

Training for CMRP One chapter a week will be reviewed each with a test the following week. Chapter 8 is the only exception because there is so much information. Each student will be required to read the chapters and be prepared to take the test. There will be no debating the answers on the test. Explain the SMRP test methods

Results In the beginning of the contract and our first and second attempt at becoming certified our pass rate was around 33% Since setting up these chapter reviews our pass rate has increased to 53% in June to 68% in October This method works if you apply yourself

SMRP 5 Pillars Of the Body of Knowledge

SMRP’s Body of Knowledge (BOK) – 5 Pillars SMRP Body of Knowledge 1.0 Business & Management 2.0 Manufacturing Process Reliability 3.0 Equipment Reliability 4.0 People Skills 5.0 Work

Chapter 1 Review After reviewing this chapter you will understand : What is a “Best Practice” What is an Asset What is Reliability What is Maintainability What is Availability What is Maintenance Cost What is Schedule Compliance

Chapter 1 Review What is a “Best Practice”? Ramesh defines “Best Practice” as an idea which asserts that there is a technique, method or process that is more effective at delivering a desired outcome than any other technique, method or process. The term "best practice" refers to those practices that have produced outstanding results in another situation and that could be adapted for A method or technique that has consistently shown results superior to those achieved with other means and that is used as a benchmark. Everyone needs to understand that “best practice” is a relative term. To some it may be a routine or a standard practice, but to others, it may be a best practice because a current practice or method is not effective in producing the desired results. Information came from out book on page 2 and the internet.

Chapter 1 Review Understanding Assets, Maintenance and Reliability What is an asset? The physical resources of an organization, such as equipment, machines, mobile fleet, systems, or their parts and components, including software that performs a specific function or provide a service; sometimes referred to as physical assets. In any organization, assets are needed to make products or to provide a service. THE OBJECTIVE OF MAINTENANCE AND RELIABILITY IN AN ORGANIZATION IS TO ENSURE THAT THE ASSETS ARE AVAILABLE, WHEN NEEDED, IN A COST EFFECTIVE MANNER. The performance of an asset is based on three factors: 1.) Inherent reliability – How it was designed 2.) Operating environment – How it will be operated 3.) Maintenance plan – How it will be maintained

Chapter 1 Review What is Reliability? Reliability, a design attribute is a broad term that focuses on the ability of an asset or product to perform its intended function. Example: A given machine is designed to make 20 washers a minute. Once the machine is installed and checked out it needs to produce 20 washers a minute, not 19 or 21. What is Maintainability? Maintainability is another design attribute. It is to ensure maintenance task can be performed easily and effectively. Example: In the design phase maintenance task should be taken into consideration. What is Availability? Availability is the probability than as asset is capable of performing its intended function satisfactorily when needed in a stated environment. Only need to understand the definition at this time. What is a Reliable Plant? A reliable plant means that the plant and its assets are available, as and when needed, to meet the customers needs on schedule and at cost.

Chapter 1 Review

Chapter 1 Review Maintenance Cost as a percent of RAV: This is calculated as maintenance cost divided by the replacement of the asset. Maintenance cost. This is the cost of maintenance for plant or facility; it includes maintenance labor, maintenance materials, contractors used to perform maintenance work, capital maintenance and cost of all projects to replace worn out assets. Replacement Asset Value (RAV): This number typically comes from engineering or company’s insurance carrier and not from accounting. Maintenance material cost as percent of RAV: This benchmark is calculated as maintenance material cost divided by the replacement asset value. We must ensure that the maintenance cost includes all maintenance material purchased for all assets in a plant, including maintenance storeroom parts and materials, parts and material used by contractors on maintenance, and capital maintenance work. Schedule Compliance: This is the ratio of maintenance labor hours consumed for jobs or task completed divided by the total maintenance labor hours available during that period.

Chapter 1 Review Maintenance Schedule. The maintenance schedule identifies jobs/task to be completed and approved in the previous week or at least three days in advance. It should cover 100% of maintenance labor. Percent of Planned Work: This measure calculates the percent of maintenance work orders where all parts, material, specifications, procedures, tool, ect., have been defined prior to scheduling the work. Production/Operations Breakdowns Losses: One important issue which directly impacts this benchmark is that all personnel from executive level to production operator must be responsible for the plants assets. Operators must see assets as something they own which will impact their lives in a positive manner. Parts Stockout Rate: This measure is based on the number of times a maintenance craft person visits the storeroom to get the parts needed versus when parts are supposed to be in the storeroom, but is not available in stock.

Summary A best practice is a technique or methodology that, through experience and research, has proven to lead reliability to desired result. A best practice tend to spread throughout an industry after a success has been demonstrated. However, demonstrated best practices can often be slow to implement, even within an organization. According to the American productivity and Quality Center, the three main barriers to adoption of a best practice are a lack of: Knowledge about current best practices Motivation to make changes for their adoption Knowledge and skills required to do so Reliability and maintainability are important asset attributes. They are usually designed into the asset to minimize maintenance needs by using reliable components that are easy to repair if they fail.