Does anyone have a nice one-page summary report template that has been successful for you in sharing your findings and recommendations with management / operations / customers? If so, would you be willing to share it on this forum?

It seems to me that many excellent PdM programs go unrecognized by others in the organization simply because we do not take the time to communicate our findings and recommendations in a clear and concise format. I would love to see what others are using to accomplish this.

Thanks,
Shelley

Hi Shelley,

I'm attaching a sample report which we are using here.Itz not 1 page anyway!!

I'm attaching this mainly to know the formats others are using!!
About the communication with management, whatever you do there will still be some gap.Ha ha ha.. Why always Condition Monitoring Group have to fight with their own management, with other reliability guys and with the plant personnel? Not for me only, it was same everywhere, i think!!!

Have a nice time!!

Vibration_Report-SPFP_I_D_Fan-_3_15-05-2006.pdf (113 Kb, 358 downloads) Sample Report

Hi Shelley--

Attached (maybe) is a example of what I use. It's just a basic Excel spreadsheet, but it does the trick and is pretty easy to update every month (I just resort, change all red font to black, add new "finds" at the bottom (in red) and modify ongoing issues (in red).

Tony

SD-WH-Caustic_PdM_Rep.xls (22 Kb, 317 downloads) Sample Report

HI Shelley W,
I see exactly what you mean. I had some problem selling the predictive dep. To the in-house management and I developed an Excel program to publicise it. The Excel program use a macro function to runs request through CSI, Ams suite ODBC driver. It then import overall reading from each point and sort it in graph by machine. It is then easy to compare overall reading from machine to machine, who’s the worse machine? Which one runs better? It is even useful for me it give you a better view of your machine and you set it up sector by sector. That way the planer or management only see the machines of interest. It helped my life, selling the predictive program.

Best regard, Marcel

Excel_overall.doc (226 Kb, 263 downloads)

Tony; very good! Similar to what I use. It's late and I have a night assignment and people are coming in. I hope to get back and post something in a few days. I also have a very formal report and running reports for areas. Later!!!!11111

My thanks to all. Interestingly, we are seeing two types of reporting, both of which are essential. First, an overview of readings/status of all equipment measured in a building, department, etc. I assume this type of report is distributed monthly or quarterly. Second, a summary of a findings and recommendations on a single piece of equipment that would be distributed as needed when action is required. I'll be working on developing a template for both types, and these examples everyone is sharing are very helpful! I'll post what I have when it's ready.

Anybody else want to share?

Shelley

Shelley,

I create a Summary report in Word with a brief descriptions of my findings and a hyperlink to a Machine Condition Report where I get more specific.

I do it in Word because it is easier than .pdf files and have never had any security problems.

Evidently I can only attach one file, so I'll post the Summary Report here and then attach a Machine Condition Report.

I am considering changing my reporting methods to something where I would post the report on my website and allow my clients to post their responses/findings, but havn't had time to do that yet.

hp021120.doc (33 Kb, 248 downloads) Summary report

This is a Machine Condition Report.

I doubt if the hyperlink will work, but it does in the real reports.

FDFAN.DOC (85 Kb, 237 downloads)

I have formal reports and then the summary and then running reports; so, I have a three phase to the reports and keep everything on a hard-drive so anyone can access at anytime.

End_of_Week_Report_336.doc (44 Kb, 249 downloads) Summary

And to the summary or rather this came first. BTW, this report is one of a series on the machine in question. Typically one comes out every month while summaries come out every week and then all managers get running reports of everything in their dept.

The report shown makes follow-up statements due to a 274% increase in vibration with projected failure in Aug '06.

381____5__Pinion_Stand_MAR.doc (556 Kb, 198 downloads) Mill Stand 5

Vibase has a good report IMHO! There are a number of good ways to do it. I think several are presented very well

You asked for a summary; saying the least with the most. Without people knowing you and your work and without having established a confidence factor with them, then I think the formal report is necessary. Maybe if you're one of those folk that have been there forever and in an environment where basically all know one another, then maybe a work of mouth will get the job done timely. Maybe I don't have enough moss under my feet.

Regardless, whatever works! It must work else the approach is wrong and you're to blame.

One thing I do is hold myself accountable; call the shot and give a time frame. Tell everyone what I'm doing and how much I'm doing. Our job sometimes keeps us out-of-sight and out-of-mind so they can form an opinion that you're sitting on a cushion and squaking about something. If you only report problem machines then they only see X# of machines and "is that all you've done"? I'm doing in excess of 5,000 pts per month and trying to give full attention to all; yes, it's about impossible and do training, IR and the like. I like to keep the curtains pulled in my office so they are off-balance not knowing when to bring in the little white suit.

Thanks Sam.

This is my monthly report to the higher ups. I keep it simple. I also periodically encourage management to ask questions. By including the cost avoidance figures for each piece of equipment, managers sometimes question the high numbers. This is a good opportunity for me to open the "black box" for them.

IVAP_Vibration_Master-2005.xls (146 Kb, 263 downloads)

Here's an example of a detailed Vibration Inspection Report from our plant. We have all the reports posted on our intranet website, categorized by Severity (WATCH/ALERT/ALARM) and by technology (Oil/Thermography/Vibration/Motor Monitoring).

Vibration_S32420ME549_20041219.pdf (255 Kb, 292 downloads)

Shelley, et.al.

One of the key areas of the disconnect in maintenance and management communication is the production of reports that prompt the decision-maker to act. We are presently working on a larger project on maintenance and management communication. Part 1 covered the history that led to the disconnect and a PROACT Root-Cause-Analysis study (see attached). Part 2 is in development and is specifically a study on the development of reports.

Howard

Maintenance_and_Management_Communication_Part_1.pdf (769 Kb, 273 downloads)

Howard,
Thanks for posting your paper. I will read it and pass it along. I think the RCA approach is excellent. When do you expect to publish part 2?

Steve,
The layout of your report is great. I also like the check boxes. One problem with reports is that writing them takes up valuable time of the technologist. Your report helps with this problem, and it presents clear information to management. Good job!

Shelley

Shelley:

It will be published by the end of July, 2006, as it is presently being drafted. There will be an announcement on ReliabilityWeb as this work runs parallel with the "Skilled Workforce in the 21st Century" project that Terry O'Hanlon and I have been working on that will be published in August, 2006 (project completed in January, 2006).

Howard

quote:

By including the cost avoidance figures for each piece of equipment, managers sometimes question the high numbers. This is a good opportunity for me to open the "black box" for them.

Well Said!!

Sharkey,
I am very interested in your method of calculating cost avoidance. I have been using one I found in the article, “A Web-Based Cost Benefit Analysis Method for Predictive Maintenance by Richard N. Wurzbach” that was posted here and I am thinking there must be different approaches. I am very interested in other approaches towards PDM program justification as well.
Thanks In Advance,

PDM_avoidance_savings_1_fitz_mill_6-12-06.xls (21 Kb, 197 downloads) cost avoidance calculator

Noisemakr, I use a simple formula.
I take production labor hrs. + mechanic labor hrs. + projected downtime hrs. in the event of equipment failure. Since we produce margarine in our facility, I use the company's lbs. per hour loss calculation. I base the projected downtime on past history of failure. So, for example, if I find a motor going out on a pd pump on a specific production line, the equation may be: 1 mech./ 2 hrs + 2 operators/2 hrs. idle + 2 hrs./ downtime = $ avoidance. I then comment on worst case scenario of not having parts in stock. This would then add significant costs such as overnite shipping, etc. I keep my figures conservative so that examples of runtime failure more than support my numbers.

Thanks Sharkey, It looks like we are calculating close to the same way. I will need to add labor costs (production and maintenance) to cover all the bases.
Good in = Good out