Maintenance - Roadmap to Reliability

While many industries are trapped in the vicious cycle of doing reactive maintenance, one of the leading questions being raised is how do we start the journey to reliability? I have been faced with this challenge a couple of decades ago. The thing is how do we begin and where do we start. This book details the step-by-step activities through the 4 Phases of TPM Planned Maintenance in achieving a level of World Class Maintenance Excellence. The author shares his experience on how to achieve such a feat.

Transitioning from a reactive to a proactive maintenance stage is not an easy task, but it is not also an impossible task. Moving up to this level of world-class will involve changing the culture of the entire maintenance workforce. The author believes that the key to everything is educating the maintenance people on what maintenance is all about. What is can and cannot do. Training is where we acquire knowledge to develop the skills required to do our job correctly right the first time around. This book contains real-life stories, case studies, and the actual results my team achieved in performing such a task. The good news is that we explain how this feat was accomplished and convert each step into a detailed step-by-step roadmap in industries can adopt.

Some highlights of this book include:

• Actual Report submitted to JIPM on TPM Planned Maintenance
• Actual Planned Maintenance Case Study and Results
• Why Planned Maintenance should be the strongest pillar in any TPM implementation
• 129 Assessment Questionnaire on the 12 Disciplines on World Class Maintenance
• Contains quizzes at the end of each chapter to gauge the comprehension of the reader
• A detailed explanation of the Preparatory Phase of Planned Maintenance
• A detailed explanation of the 4 Phases of Planned Maintenance
• How Reliability-Centered Maintenance can be integrated into the higher phases of PM
• Survey on the Top 10 Problems on Preventive Maintenance
• Important Lessons on Implementing TPM

The generic approach to Planned Maintenance is done in 4 Phases excluding Phase 0 which is the Preparatory Phase. One of the important activities of Phase 0 is creating a Machine Ranking for all equipment and assets to determine which machines to focus on first. Phase 1 is all about restoration activities which are done in parallel with Autonomous Maintenance Step 1 activities on Initial Cleaning which aims to bring the equipment back to its original basic condition.

The last 2 Phases will be focused on creating a sustaining activity so that the equipment will not revert back to its old existing condition. An added feature to this book includes a 129 Assessment Questionnaire which provides a scoring system to determine where your industry currently is from the worst to a level of World Class Maintenance. This assessment questionnaire will also provide your industry with its strongest discipline and those disciplines that need to be strengthened.