Hi

I'm doing a project on optimizing the maintenance planning process and the maintenance plans using the 5S process. Can anyone assist

Do you mean the Japanese 5S concept?

First thing have you got the existing process? Can we see it in order to be able to comment?

The basic ISO9000 process is the PDCA cycle i.e. Plan, Do, check & Act.

5S is part of the Kaizen philosophy. I was involved in a a couple of Kaizen projects a few years ago and AFAIAC it does work.

Specifically 5S information can be found on Wikipedia, http://en.wikipedia.org/wiki/5S_%28methodology%29

Giga,
Optimizing implies finding the most effective way to achieve the end result. Often it is interpreted as finding the cheapest, a view I don't share.
The purpose of maintenance is to assure capacity and safety, and to do this at the lowest possible cost.
We can assure capacity by high reliability and/or maintainability; safety depends on high reliability. It so happens that high reliability also results in low cost. So the bottom line is to go for high reliability, as it influences all outputs favorably.
We can achieve high reliability by a series of steps;
- Do the basics right: eqpt. kept clean, dry and correctly lubricated, balanced. aligned, bolts tight, good housekeeping
- Eliminate defects progressively by using Root Cause Analysis
- Identify the right maintenance work to do and when to do it, with tools such as RCM.
- Do all this work on time and to the right quality

Then sit back and enjoy high Uptimes, good Safety and low costs!

Giga,
I agree with Vee. You can't optimise the planning process if you dont have the right PM to start with. If you have the right PM, then you can plan properly. You can't have an optimal plan if you are doing the wrong PM, duplicating effort, doing the PM at the wrong interval etc. You must of course have the right skills and knowledge, time and materials, and culture that cares.
If you have these attributes, reliability will increase and the cost redution will look after itself.
You should take a look at PM Optimisation as well as RCM. Our website at www.pmoptimisation.com.au has lots of info
Regards
Steve
Director OMCS International

Steve,
Hi there!
With respect Steve, I am not sure we are on the same page; I did not mention pre-existing PMs at all. In fact, I don't believe we need PMs in place before optimizing the maintenance plan. I am of the view that we can actually build an optimized plan for a new facility as well.
My point is that we need to build the foundation of quality and compliance first before working on the superstructure. The latter process starts with defect elimination through RCA. For a new facility of course we can start with RCM, RBI and IPF while the project is still in electrons at the detailed design stage.

Hi Vee,
what is your definition of a maintenance plan? Perhaps this is where we are on different pages.

The five S's are ...

Sorting
Simplifying
Sweeping
Standardising
Sustaining

I am not sure if the 5S approach is the best approach for optimising the maintenance planning process. As I understand it 5S is more commonly used to "tidy things up".

quote:

You can't have an optimal plan if you are doing the wrong PM, duplicating effort, doing the PM at the wrong interval etc.

Steve, the question is not about the definition of a maintenance plan so let's stay on topic.

I think you are missing the fact that the OPs point was that he wanted to optimise his maintenance plans. This clearly suggests that he has already recognised the need to do so.

Bryan,
A maintenance plan to me is what maintenance needs to be done on an asset. This can include preventive, predictive, corrective, and failiure finding tasks.
I am talking about finding the optimum mix of these.
Please let me know what you guys consider to be a maintenance plan... are we only talking about reactive and corrective?
Rgds
Steve

I think you are taking the thread off topic.

Perhaps if someone was to answer my question, then we can see if I am or not.
Bit confusing at the moment from my perspective.
Rgds
Steve

My point was that this is not your thread. If you have a question why not start another thread?

Hi Steve,
Yes, I am with you in defining a maintenance plan. In my view it has the following elements:
A) Deciding in advance what work to do and when to do it: Preventive actions
B) Having actions in place to jdentify trends of failures that have already commenced so as to predict time of failure: predictive actions
C) Testing items to identify whether they are in working or failed state: detective actions
D) Carrying out corrective restoration after or just prior to predicted time of failure: corrective actions

In each facility, depending on the consequences of failure, there is an ideal mix of A, B, C and D, which we can find using e.g., RCM, RBI and IPF. That, for me, is the optimal solution.

My earlier comment was that a prerequisite for optimization is that have effective systems to ensure quality and compliance of basics - equipment clean, dry, lubricated, aligned, balanced and with tight bolts. These do not necessarily need PMs, only the right attitudes and behavior.

Brian,
I think you are being a little harsh on me.

quote:

My point was that this is not your thread. If you have a question why not start another thread?

Vee says we are not on the same page, I seek clarification of a definition.
I would have thought this was fine.
Rgds
Steve

Giga's questions was ...

quote:

I'm doing a project on optimizing the maintenance planning process and the maintenance plans using the 5S process. Can anyone assist

This clearly suggests that he already has maintenance plans and a maintenance planning process. He is doing a project which requires him to use 5S to optimise these. He has asked for assistance. I am afraid I cannot see the need to discuss the definition of a maintenance plan?

Your point ...

quote:

You can't optimise the planning process if you dont have the right PM to start with.

His plant maintenance department has already acknowledged that their PMs need optimising. That is what the thread is about.

So I guess Brian, if someone is trying to undo a screw with a hammer, you would not be suggesting he use a screw driver. You would be trying to find a way he can use the hammer to get the screw out.
Steve

Hey Giga,
come back... this is getting out of control.
Help.

Giga,

You may use 5's most specially in the documentation process where you can easily access your document and maintenance files.

Use of color coding / tags / stickers would be of help in your 5's and most specially the use of visual controls for your equipment for easy fault finding.

My Warm Regards,

quote:

So I guess Brian, if someone is trying to undo a screw with a hammer, you would not be suggesting he use a screw driver.

No, If I saw someone doing this I would accept that they were totally incompetent and beyond redemption. I am happy to assume that this is not the case with Giga.

All he/she asked was for assistance with 5S. That is not comparable with trying to undo a screw with a hammer, is it?

Bur Giga appears to be gone so there is probably no point in discussing it further.

Bryan, Steve,
Giga posted his question nearly two weeks ago. Since then there has been complete silence. I suggest we all stop this thread completely till we hear from Giga again, maybe there is no further interest on the part of the initiator.