Analyzing and eliminating the root cause of a failure is a powerful tool for improving plant reliability. At IDCON, we call this process Root Cause Problem Elimination (RCPE). We find that this term more accurately defines the desired outcome of the process. 

Imagine you work in a mill as a mechanic and get a work order that states: Replace bearings on a press roll due to high vibration level. You complete the work and the damaged bearings and seals were replaced according to the plan. The machine was started up and is now producing paper again.

"Gemba" is a Japanese word meaning the actual place where value is created, or where actions are executed. It includes Gemba walks to the actual place to observe, learn and improve work.

A key inspection for gear reducers is to listen for noise. The inspection should focus on a change in the sound.

On April 20th at 10:30-11:00 AM (EST) in his second webinar in the “Keeping it Simple” series, Reliability and Maintenance Management expert Christer Idhammar gives you a glimpse into why “knowing why” is important in managing maintenance and how knocking bolts became the catalyst behind Christer’s philosophy. You’ll also learn some forgotten truths about managing maintenance processes. Join us through ...

Catch up with Tor's latest installment in the series "How to Document Cost-Effective Preventive Maintenance" here.

When it comes to existing PMs, the first thought is usually to search in the Computerized Maintenance Management System (CMMS). Of course, this is a valuable resource, but we may be missing other activity happening in departments of the plant, mill, or mine. It is very common that different crafts/departments have set up their own Preventive Maintenance Systems for components and equipment.

In terms of Maintenance Methods, there are three choices for existing equipment. They are Operate to Breakdown, Fixed Time Maintenance, and Condition Based Maintenance. Operate to Breakdown: The equipment is run until it breaks down. Fixed Time Maintenance: The replacement of parts or equipment on a fixed/scheduled frequency.  Condition Based Maintenance: The problem is found and fixed at the time when it is discovered. It is a common assumption that Condition Based Maintenance is always the most cost effective. While this is commonly the case, it is not always true.

What is a component? IDCON uses the word “component” to describe an item that is highly repetitive for preventive maintenance purposes.  For example, the AC motor on the infeed hydraulic unit is composed of several components or machine elements. The infeed hydraulic unit is a highly repetitive unit often found in paper mills, refineries, mines, etc. AC motors are a component that is reoccurring as well.

So, we have completed our Criticality Analysis. What’s next? In Part 5 of this series, we will cover the importance of using an equipment list while performing Preventive Maintenance, how to use the equipment list most effectively, and provide an example and template of a well-organized equipment list.