Maintenance Phoenix

Proactive Maintenance Foundational Requirements

Posted by Mike Gehloff on Feb 11, 2013 10:47:06 AM
Mike Gehloff

Proactive Maintenance – Foundational Requirement

Proactive Maintenance Foundational Requirement # 1 -  "Striking the Right Balance Between PM and PdM”

Having the right balance between PM and PdM is key to successful identification of proactive work. Identify how the PF Curve works with Proactive Maintenance vs Reactive Maintenance . The early detection of a defect on the PF Curve provides maintenance more time to plan and schedule the work before equipment fails.

A good example would be; Vibration Analysis identifies a bearing defect on a large electric motor. Where should it be identified on the PF Curve? In Proactive Maintenance the defect would be detected in Priority 4 and 5 on the PF Curve. By identifying this work early enough we have time to plan and schedule corrective work before the equipment fails and mitigates interruption to production or operations. In addition there is a direct correlation between early detection of a defect and maintenance costs.

Review the PF Curve and the Work Priority Distribution Chart and post your comments or questions. Remember this is a learning exercise for everyone so please share your ideas or questions so we can learn from each other.

A 30 minute WebEx is scheduled – “The Foundational Requirements for Proactive Maintenance”, Friday, February 15 at 11:00am EST (USA). If you are not registered and would like to join send me an email at


Proactive Maintenance Foundational Requirement #2 - Managing the Maintenance Function

Managing the Maintenance Function in a Proactive State is very different from managing the Maintenance Function in a Reactive State. In a proactive state the Maintenance Function is managed by people where in a reactive state the Maintenance Function is managed by the equipment. How do you know? Look at the numbers below for Proactive Maintenance in labor hours. In reactive maintenance one would be lucky to identify what category all the labor hours are assigned and if they did they would be mainly focused in Priority 4 and 5 work. The key is to reduce reactive labor hours and increase the proactive labor hours. The hard question is “how”.

Work Priority Distribution (3)

Reactive vs Proactive Maintenance Hours 

Managing the Maintenance Function in a Proactive State requires effective leading and lagging KPIs which helps maintenance management understand the behavior of their maintenance organization and only then can adjustments be made to move the organization in the right direction.

What are your thoughts?


Reactive Maintenance vs Proactive

Proactive Maintenance Foundational Requirement #3 – Failure Elimination

Trying to Managing Equipment Failures is difficult for most organizations in the World. Failure Elimination is one the foundational elements found in the Best of the Best Companies in the World and in proactive maintenance it is a requirement.

The formation of small teams of craft personnel (ex: team = 2-3 mechanics/electricians – operators are engaged by the team as required) are used to focus on the cause, develop a solution, and execute the solution for repetitive failures, is the most simple and effective method used by many of these companies.

At one company, which has won numerous awards for Excellence in their Maintenance and Reliability Program has had a simple failure elimination program in place for over 30 years. This program involves maintenance personnel and operators who resolve repetitive failures at their level. There is a common understanding that repetitive problems are reviewed for cause and improvement actions are developed.  Equipment failures are seen by all levels of plant staff to be unacceptable. There are examples in mobile equipment, overhead cranes, and operating equipment where equipment design was inadequate for the operation and the craft crews developed upgrades that would eliminate failures.

In Proactive Maintenance the development of a failure elimination culture throughout the organization is a requirement and must imbedded and accepted by all.  Failure elimination needs to be simple (mainly applied by maintenance and production personnel) and most of the time informal, will eliminate a large percentage of your equipment failures and problems.

Your thoughts and comments please!

More discussion this topic at the Reliability Engineering Fundamentals Workshop in Charleston, SC - March 5-7,  join Andy Page and I for this awesome event. This is training is for at all levels of maintenance and reliability leadership and practitioners.

Here are a few items which may help you in this journey to Proactive Maintenance. I would appreciate your comments.

What do you consider Foundation Requirements for Proactive Maintenance? Please comment.











Tags: Condition Monitoring, P-F Curve, PdM, Predictive Maintenance, RCM, Failure Modes, Maintenance, Maintenance Planning, Maintenance Strategy, PM, Preventive Maintenance, asset reliability, Alcoa Mt Holly, Alumax Mt Holly, Asset Health, asset integrity, asset management, Asset Optimization, Asset Reliability, Equipment Issues, Equipment Maintenance Plan, Evaluate PM, failure elimination, Failure Reporting, FRACAS, known best practices, maintenance best practices, Maintenance Culture, Maintenance Excellence, maintenance manager, Maintenance Processes, Maintenance Scheduling, Maintenance Technician, Nowlan and Heap, Pdm Strategy, PF Curve, PM Metric, Proactive Maintenance, Reliability Based Maintenance, Reliability Engineer, Reliability Processes, world class maintenance, World Class Maintenance

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