Home Health Case Studies in Maintenance and Reliability: A Wealth of Best Practices
The operations manager invited the shift supervisor for this exercise. When he learned what he had to do, the shift supervisor requested that his senior panel operator also be allowed to come and help him. We scheduled the exercise to take place after the shift change when both these people would be free from their duties.
The two men came at the appointed time. Both were a bit nervous to face the forum in which their big boss, the operations manager, was also present. On my suggestion, the operations manager himself took the lead in developing the tally.
They generated the following Table 31.1,(shown on the following page).
The participants themselves found the result of the exercise incredible. Indeed, they could account for less than 75% of the time as shown in the table, and this included some maintenance work already being done by operators. This convinced them to accept additional alternative work for operators.
Type of Maintenance Work for Operators
Operators' unstructured time should be utilized only for alternative work, which we will call front line maintenance, as illustrated in Figure 31.1.
The following is a description of these tasks:
• Derive the tasks from RCM/RBI analysis results. These will be preventive maintenance tasks identified by a review in which operators have themselves participated. Hence they are more likely to accepted. Leave the specialist tasks for specialists.
Table 31.1 Operator Workload
Before operators can start doing some of these tasks, we may need to give some focused training.
The refinery now uses nearly 25% of their operator time in front-line maintenance activities.
Figure 31.1 Front-line Maintenance Tasks
We will always find many defenders of the status-quo. Challenging these and understanding the factual situation can help demolish such citadels.
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