A maintenance organization is a support function that keeps the product flowing to the customers. The direct customer for maintenance is the Production or Operations department. It is the task of maintenance to provide as much equipment availability as possible. In this capacity, maintenance is an asset when availability meets demand and a “necessary evil” when equipment is down for repair.
Maintenance philosophies range from a “run until it breaks” mentality to a continuous monitoring and repair program. Equipment criticality, location, cost and types can be used to determine the philosophy for equipment. But how do you know when to do maintenance? Most facilities start with a preventive maintenance program as recommended by the equipment vendors.
TTS’ comprehensive services provides a path to world class maintenance. We analyze conditions and implement plans to improve staff capabilities, documentation deficiencies, and process weaknesses. We work as your partner for as much of the process as you require.
The first step in an improvement plan is to assess your current condition. An external organization brings an unbiased evaluation of your people, processes and equipment operation.
An assessment of your Maintenance operation is provided through a detailed review of 18 areas of organization and a comparison against benchmarked standards. Areas include:
- Management Structure
- Organizational Climate
- Training & Growth
- Work Cycle
- Preventive Maintenance
- Planning & Scheduling
- Parts Management
- Maintenance Staffing
- Maintenance Supervision
- Predictive Maintenance
- Equipment & Tools
- Business Impact of Maintenance
- Quality Control
- Asset Assessment
- Management of Change
This assessment identifies the good performing areas as well as the areas with potential for improvement. TTS works with our clients to construct development plans to identify the impact of implementing changes.
Proper maintenance begins with a talented workforce. Your maintenance staff’s performance depends on several factors:
- Knowledge and Skill Level
- Proper Tools for the job (procedures, test equipment)
- Adequate time and Motivation
TTS will work with your team to determine the areas needing improvement and develop an action plan. Knowledge and Skills are tested with
- Written Exams
- Performance Testing
These tests can be used for initial hiring, advancement or establishing a training program.
A maintenance organization must select the equipment that is most critical for the performance of the facility. This equipment is analyzed for safety functions and effect on facility performance to determine criticality rankings. TTS works with our clients to establish criticalities and develop the maintenance philosophy for equipment. Work procedures are developed and periodicities determined with site input for the most effective maintenance programs.
TTS performs this service for one of the largest petrochemical companies in the world.
Documentation of equipment relationships, procedures and performance is maintained by a computerized maintenance management system (CMMS.) Many types of management systems exist with some companies still using filing cabinets and paper. The computerized system offers many advantages in organization. TTS has worked with many vendors of CMMSs to:
- Best of Breed
- Enterprise Solutions
- Data Migration and Optimization
Implementing a new process typically has a large learning curve. This causes delays and excess costs getting started. TTS has a wide range of experience implementing processes across industry. We can guide you through the startup phase and provide support when you need it the most. Services include:
- Establishing PM programs
- Development of KPIs
- Procedure Development and Deployment
- Total Productive Maintenance
Safety is always a primary concern in industry. Accidents cause lost time, damage to equipment and injury to personnel. TTS supports our clients safety efforts with:
- Lockout / tagout Evaluation and Development
- Arc Flash analysis and Guidance
- OSHA Training