Reduce Maintenance Expenses

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PM Element 6. Planned Activities

The target is not to reduce the number of tradesmen in the factory. The main objective is to change from a reactive approach (firemen) to a proactive approach (preventing breakdowns). The factory needs to develop a system of planned activities to use the maintenance resources more efficiently. In this document planned activities means:

Time Based Maintenance,

– Condition Based Maintenance,

– Corrective Maintenance (Improvements),

– Abnormalities Correction (F-Tags),

– Lubrication.

Good planning for these activities will allow a reduction in maintenance costs just because the resources are being better utilized, and also are being used to reduce the breakdowns in the factory.

INDICATORS

As in the efficiency indicators, the costs indicators will help to drive the activities for Maintenance Expenses Reduction. It is possible to divide Maintenance Cost into four categories:

– Internal Labor,

– Third Parties Services,

– Materials,

– Spare Parts (from Supply Room).

Materials are divided in two categories because they have the same purpose, the management and purchasing are different. Monitoring materials in different categories will be beneficial.

In the next page there is an example of how you measure and monitor maintenance cost. In this case Internal Labor is monitored in a different graph.

TRANSFERRING  ACTIVITIES

One way to reduce maintenance expenses is to transfer some activities to the operators. These activities normally are:

-Small Repairs

-Inspections

-Lubrication

The first step is to identify which activities will be transferred to the operators. Some criteria would include:

– Frequency (normally within a month)

– Special Knowledge

– Height

– Special Tools

– Downtime

– Time to perform/ Number of Activities

The following flow chart describe this activity.

To begin transferring activities to operator make a list with the activities that will be transferred, the current situation, and who will be responsible in the future.

Every time we talk about transferring activities, the first thing we think is to transfer activities from the tradesmen to the operators, but sometimes it is necessary to transfer from third party (contractors) to tradesmen.

The next page will show a list of activities to be transferred, and an example of One Point Lesson utilized to train the operators.

MONTHLY COST REVIEW

Another important tool to help in the Maintenance Cost Reduction is a Monthly Analysis. Maintenance Managers, Maintenance Planners, Tradesmen and other people responsible for maintenance expenses need to attend to this meeting.

The idea is to analyze the major expenses for each kind of expense (third party, material and spare parts). The questions to be answered during these meetings are:

1) What caused this cost?

2) Was it a natural or forced deterioration?

3) Was the problem solved?

4) Is it possible to make some improvements to reduce this expense?

5) Which actions will be taken to reduce this cost in the future?

In the next page there is an example of a board to help the discussions.

 

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