In our plant, we are continually upgrading and changing our machinery and processes to meet demands. Our lines have project managers/engineers as the Line Supervisors. For reliability, we are still in the infancy stage for our current equipment. While I am trying to manage the reliability of our older equipment, the Line Supervisors are constantly changing things. So, in an effort to manage the reliability of our new equipment coming in, I came up with a checklist for our Supervisors to use. I would appreciate any comments, adds, or feedback:

This checklist should be used prior to the installation of any new or substitute equipment.

1. Will the failure of this application impact production time, if it is down for less than one day? If yes continue to step 2, if no, continue to step 5.

2. Is this a single point failure design? If the answer is yes, work with reliability engineer to determine requirements for redundancy.

3. How will the condition of the application be monitored? Inform the Reliability Engineer that there is new equipment in need of condition monitoring.

4. What spare parts need to be stocked?

5. What consumables need to be stocked?

6. Are all drive and conveyor belts within the plants standardization scheme?

7. Are all motors and gearboxes within the plants standardization scheme?

8. Have all surfaces, including welds, been treated/covered to prevent corrosion?

9. Is there a service manual for the equipment? If so, provide to Store Room for scanning into MP2.

10. What are the OEM maintenance recommendations?

11. What preventative maintenance needs to be performed and how often? Inform the Reliability Engineer that there is new equipment in need of PM.

12. Should this be done by an operator or by a maintenance person?

13. What safety concerns need to be abated or mitigated?

14. Are all controls labeled, to include power and lockout locations?

15. What training needs to be accomplished for operators? For Maintenance?

16. What Supervisor Plans (these are our operating instructions) need to be added or modified?

17. Will this equipment need to be added to MP2? If so, notify the Store Room.

18. What controls will be required? Contact Controls Engineer to request PLC integration. Provide electrical schematic and existing controls programming to Controls Engineer and Store Room.

Jack J,
I like it a lot. It asks the questions that need to be asked.
Here are a couple of comments: ref#
#6, #7: Has the equipment already been purchased at this point? Previous to purchase is the time to ask these questions as you might well have the chance to standardize. It's still a good idea to ask them after purchase to make them think about it.
#9: Insist on PDF original versions whenever possible besides printed copies. The original versions have links and such that PDF copies don't.

Nice job.
J-

Jack,

If you can, get involved in the factory acceptance testing before taking delivery of the equipment. A very good way to be pro-active with new equipment.

I have not completed the SOP for a FAT but have included all the technologies we have i.e., vibration analysis, IR, Ultrasonic, and laser alignment tools. We have caught several issues by being there, on the factory floor. More about my FAT experience can be seen here. http://maintenanceforums.com/eve/forums/a/tpc/f/2091034...461077862#1461077862

Nice initiative, some remarks:
I could see three distinguished phases

1) Before buying, items 1, 2, 3, 6, 7, 13 and 18

2) The actual procurement process, items 4, 5, and others

3) The commissioning, items 8, 14 and 16

The "checklist" (marking things off with a check mark) I see more in the commissioning phase. The rest is more IMHO like a questionnaire where you need to write a lot.

Attached is a maintainability checklist, when I used it the very first time, it scared the h.. out of the engineers!!

After that I was getting requests for this checklist especially when they knew there was a chance I would be in the surroundings of the new equipment/installation during project handover.

Regards

This message has been edited. Last edited by: svanels,

Mech_MasterCheck.pdf (35 Kb, 70 downloads) Maintainability checklist

This looks good.

A suggestion: have you considered the implications of 'hidden failure'? E.G. something that fails but goes unoticed by the operating crew in the normal course of their work. This is really important if there is a trip of safety interlock device, which if it fails and is not noticed, if a transient then occurs that requires the safety device or interlock to work, you will suffer unacceptable consequences (the reason you fit a safety device in the first place).

What is the normal operating context of the machine? is it a standby machine perhaps that cuts in on some kind of demand signal? what if the device sending that demand signal fails (unoticed) - what are the consequences?

Does your maintenance regime need to include 'functional' failure finding tasks that uncover hidden failures.

If your plant changes is operating procedures or institutes manpower reductions in the operating crew, do you reassess your risk for liability to hidden failure?

Hidden failure, and failure finding tasks are integral in defining a maintance regime within the RCM framework.

Regards - Charlie

Jack, I too like this application.

As an addition I would add the importance of the lube survey/ first fill. Answer all the lubrication questions and procedures correctly and it is done forever, all you can do after is improve the process as opportunities arise.
Well done, HN