In the previous article, I wrote about prevention in the UR department. Then, the issue of review plans was also touched upon. In the following text I would like to present how to write review plans, or how to create overview cards.
Assuming that we do not have CMMS class software, so we will create review plans in the “paper” version, that is, using Excel known to all. To create a good plan to start with, we need to identify all points on the selected machine or device that may be potential causes of failure. I am talking here about all bearings, chains, lubrication points, etc., also for the safety of people working on machines, it is worth reviewing the operation of safety switches, limit switches, etc. Moreover, if we operate in BRC, IFS or HACAAP systems, it is worth to add the state of all elements plastic or glass, if any, on the machines, so as to ensure the safety of the product.
Having identified control points, we can create a table in Excel, which can look like this:
In the first column, enter which device is subject to inspection, then describe the action the technician must perform. The next – the third column is supplemented with the frequency with which you need to repeat the given activity, frequency setting is one of the most difficult tasks.
We must take into account the manufacturer’s recommendations, our failure rate, and the optimization of prevention costs in relation to our KPIs (but this is a topic for a separate article). In the fourth column it is worth to include the mode in which a given action can be performed, i.e. the ability to perform it while the device is in operation or maybe we must stop it? This is important information for the UR department, because it gives managers of technical departments information whether the date of the review work must be agreed with the production planners.
Then, in the fifth column, enter the material needed for the work (eg type of grease) or if the inspection activities require measurements, you can enter in this column the correct values for a given measurement. The sixth column is photos of places subject to breakdowns, useful for rotating teams of technicians or implementation of new people in the area of work of the technical department, significantly shortens the time for searching and identifying inspection sites. The remaining part of the card is simply verification of the work done by technicians together with the assessment of the technical condition of the components being viewed. I wrote about grading previously.
We can give this printed card to the technicians so that they can work in an orderly manner. Of course, the above card is just an example, it can be expanded with additional elements or omitted existing ones. Creating such a card is the first action to start thinking and working preventively, and if we look long-term, working out a standard of reviews and its adherence is also a great foundation for implementing the CMMS class system in the UR area.
The activities described above assume that preventive work is carried out only by the maintenance department. What if machine operators were involved in preventive activities?