Maintenance - Roadmap to Reliability

Sequel to World Class Maintenance Management - The 12 Disciplines

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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, or 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 it can and cannot do? Training is the backbone of any cultural change, This is where we acquire knowledge to develop the skills required to do our jobs 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 Phase into a detailed step-by-step roadmap that 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 ¿ A detailed roadmap for each Planned Maintenance Phase ¿ 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.

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Rolly is a seasoned international maintenance and reliability consultant with over 30 years of solid experience in the field. He has been invited to different countries and has conducted reliability and maintenance training in United Arab Emirates, Qatar, India, Malaysia, Indonesia, Brunei, Thailand, Nigeria, Bangladesh, South Africa, China, and Botswana. His maintenance training portfolio includes maintenance and reliability courses on TPM, Lubrication, Tribology, Condition-Based Maintenance, RCM, RCFA, TPM Planned Maintenance, Autonomous Maintenance 7 Steps, World Class Maintenance Management, The 12 Disciplines, Oil Contamination Control, Maintenance Indices, and KPI's, Maintenance and Reliability Management Strategies and much more. Rolly previously worked with Amkor Technology Philippines as a TPM Senior Engineer, an industry engaged in manufacturing Integrated Circuit products and spearheaded their Planned Maintenance organization, composed of maintenance managers and engineers. He was also responsible for dramatically reducing unplanned breakdowns in their TPM Journey and RCM implementation on their Facilities AHU units and substation equipment. Rolly is currently working as an independent reliability and maintenance consultant. Rolly is a graduate of Mechanical Engineering from Mapua Institute of Technology in the Philippines, batch 1985, and passed the licensure board examination the following year in 1986. With 30 years of solid experience, he had worked in various industries from shipping, woodworking, foundry, cast-iron machining, assembly lines, semiconductor manufacturing, and the mining industry. Here, he gained hands-on experience and understanding of TPM and RCM, respectively, a strategy from both the west and the east. His last corporate employment was in 2002, where he worked as a technical training specialist at Lepanto Consolidated Mining Industry. In 2005, Rolly retired early from the industry and decided to establish his own consulting business, RSA Reliability and Maintenance Consultancy Firm, where he dedicates his time and passion for working as an independent reliability and maintenance consultant. He provides in-house training, consultation, and facilitation to different maintenance and reliability best practices.