Engineering & Mining Journal

DEC 2015

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DECEMBER 2015 • E&MJ; 79 www.e-mj.com M A I N T E N A N C E Policies—Spelling it Out Departmental Responsibilities • Each department manager will ensure compliance with the poli- cies covering the conduct of maintenance. • Each department will develop and publish procedures by which other departments may obtain their services. • Operations will be responsible for the effective utilization of maintenance services. • Maintenance will be responsible for developing an effective maintenance program, educating personnel on its elements and carrying it out diligently. They will also make effective use of resources and ensure that quality work is performed. Terminology • Maintenance will publish workload definitions and appropriate terminology to ensure their understanding and proper utilization. Work Order System • The work order system will be used to request, plan, schedule, assign and control all maintenance work. At the discretion of each depart- ment manager, the system can be used to control work requiring effective control, resource use, cost and performance information. Preventive Maintenance (PM) • Maintenance will conduct a detection-oriented preventive main- tenance (PM) program. The program will include equipment in- spection, condition-monitoring, and testing to help uncover equip- ment deficiencies and avoid premature failure. The PM program will also provide lubrication services, cleaning, adjusting and minor component replacement to help extend equipment life. • Comprehensive predictive techniques will be integrated into the PM program to ensure modern asset management and reliabili- ty technology is fully utilized. • PM will take precedence over every aspect of maintenance ex- cept bona-fide emergency work. • No major repairs will be initiated until PM services have estab- lished the exact condition of the equipment and elements of the repair have been correctly identified. • The overall preventive maintenance program will be assessed annual- ly. Assessors will ensure that it covers all equipment requiring servic- es and that the most appropriate types of services are applied at the correct intervals. The performance of the PM program in reducing equipment failures and extending equipment life will be verified. • Equipment operators will perform appropriate preventive mainten- ance services to help ensure the reliable operation of equipment. Planning and Scheduling • Planning and scheduling will be applied to comprehensive jobs (e.g., overhauls, major component replacements, etc.) to ensure that work is well-organized in advance, properly scheduled and completed productively and expeditiously. • Criteria will be developed to help determine which work will be planned, and all major repairs meeting the criteria will be subject ed to planning procedures unless an emergency repair is indicated. Information • Maintenance will develop and use information concerning the utilization of labor, the status of work, backlog, cost and repair history to ensure effective control of its activities and related economic decisions such as equipment replacement. • Minimum necessary administrative information will be developed and used. • Performance indices will be used to evaluate short-term accomp- lishments and long-term trends. Organization • The maintenance workload will be measured on a regular basis to help determine the proper size and craft composition of the work force. • The productivity of maintenance will be measured on a regular, con- tinuing basis to monitor progress in improving the control of labor. • Every effort will be made to implement and utilize organizational and management techniques like teams or Reliability Centered Maintenance (RCM) to ensure the most productive use of maintenance personnel. Setting Priorities • Maintenance will publish a priority-setting procedure that allows other departments to communicate the importance of work and maintenance to effectively allocate its resources. • The procedure will facilitate the assignment of the relative importance of jobs and the time within which the jobs should be completed. Maintenance Engineering • Maintenance/reliability engineering will be emphasized to ensure the maintainability and reliability of equipment. • Current technology will be utilized to facilitate effective maintenance. • Equipment modification requires approval by maintenance engi- neering and assurance of future reliability and ease of maintenance. • All new equipment installations will be reviewed by maintenance engineering to verify work quality and to ensure their subsequent maintainability. • Standards will be developed and applied to all instances of repeti- tive periodic major maintenance like major component replacements. • The most effective predictive techniques will be used to supple- ment condition-monitoring carried out as part of the preventive maintenance program. Material Control • Established procedures for purchasing and the withdrawal or return of stocked materials will be strictly adhered to by all plant personnel. • Parts will not be removed from any unit of equipment and used to restore another unit to operating condition without explicit authorization from the maintenance manager. • Maintenance will return unused stock materials to the ware- house. Maintenance will not attempt to store such materials. Non-maintenance Work • Engineering, operations and maintenance are jointly responsible for ensuring that all non-maintenance projects (construction, modi- fication, equipment installation etc.) are necessary, feasible, prop- erly engineered and correctly funded before work commences. • Maintenance is authorized to perform project work such as: con- struction, modification, equipment installation and relocation only when the maintenance workload permits. Otherwise, contractor support will be obtained subject to the current labor agreement. • Equipment modifications will be reviewed to determine their necessity, feasibility and correct funding prior to the work being assigned to maintenance. All such work will be reviewed by maintenance engineering before work commences.

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