The traditional maintenance planning department typified
the old maxim in action. A key responsibility of this department was usually to compile maintenance schedules for
all the equipment in the plant. Maintenance planners often
devoted immense amounts of time and energy to this exercise (the author knows – he was one once). However, more
often than not, their schedules died when they reached the
shop floor. This happened for two main reasons:
• technical validity: the planners who wrote the schedules
were usually out of touch with the equipment (if they had
ever been in touch to start with). As a result, they often
had a less than adequate understanding of the functions,
the failure modes and effects and the failure consequences
of the assets for which their schedules were being written.
This meant that the schedules were usually generic in
nature, so people who were supposed to do them often
saw them as being incorrect if not totally irrelevant
• ownership: people on the shop floor (supervisors and
craftsmen) tended to view the schedules as unwelcome
paperwork which appeared from some ivory tower and
disappeared after it was signed off. Many of them learned
that it was more comfortable just to sign off the schedules and send them back than it was to attempt to do them.
(This led to inflated schedule completion rates which at
least kept the planners happy.) The main reason for the
lack of interest was undoubtedly sheer lack of ownership.
The only way around the problems of technical invalidity and lack of ownership is to involve shop floor people
directly in the maintenance strategy formulation process.
This is because they are the ones who really understand
how the equipment works, what goes wrong with it, how
much each failure matters and what must be done to fix it.
The best way to access their knowledge on a systematic
basis is to arrange for them to participate formally in a
series of meetings. However, it is essential to ensure that
these meetings do not just become another bunch of inconclusive talkfests. This can be done by arranging for the
participants to be trained professionally in the use of
RCM2, and to provide them with skilled guidance in the
application of this technique.
Done correctly, this not only produces schedules with a
much higher degree of technical validity than anything
that has gone before, but it also produces an exceptionally
high level of ownership of the final results.
(A word of caution at this stage: It is wise to steer clear
of the temptation to use external contractors to formulate
maintenance strategies. An outsider's sheer ignorance of
almost all the issues discussed in connection with maxims
1 through 11 insofar as they affect your plant means that all
you are likely to get is a set of elegantly completed forms
that amount to little or nothing. Using such people to develop maintenance programs is to wander into the hazy – and
dangerous – region where delegation becomes abdication.)
The traditional maintenance planning department typified
the old maxim in action. A key responsibility of this department was usually to compile maintenance schedules for
all the equipment in the plant. Maintenance planners often
devoted immense amounts of time and energy to this exercise (the author knows – he was one once). However, more
often than not, their schedules died when they reached the
shop floor. This happened for two main reasons:
• technical validity: the planners who wrote the schedules
were usually out of touch with the equipment (if they had
ever been in touch to start with). As a result, they often
had a less than adequate understanding of the functions,
the failure modes and effects and the failure consequences
of the assets for which their schedules were being written.
This meant that the schedules were usually generic in
nature, so people who were supposed to do them often
saw them as being incorrect if not totally irrelevant
• ownership: people on the shop floor (supervisors and
craftsmen) tended to view the schedules as unwelcome
paperwork which appeared from some ivory tower and
disappeared after it was signed off. Many of them learned
that it was more comfortable just to sign off the schedules and send them back than it was to attempt to do them.
(This led to inflated schedule completion rates which at
least kept the planners happy.) The main reason for the
lack of interest was undoubtedly sheer lack of ownership.
The only way around the problems of technical invalidity and lack of ownership is to involve shop floor people
directly in the maintenance strategy formulation process.
This is because they are the ones who really understand
how the equipment works, what goes wrong with it, how
much each failure matters and what must be done to fix it.
The best way to access their knowledge on a systematic
basis is to arrange for them to participate formally in a
series of meetings. However, it is essential to ensure that
these meetings do not just become another bunch of inconclusive talkfests. This can be done by arranging for the
participants to be trained professionally in the use of
RCM2, and to provide them with skilled guidance in the
application of this technique.
Done correctly, this not only produces schedules with a
much higher degree of technical validity than anything
that has gone before, but it also produces an exceptionally
high level of ownership of the final results.
(A word of caution at this stage: It is wise to steer clear
of the temptation to use external contractors to formulate
maintenance strategies. An outsider's sheer ignorance of
almost all the issues discussed in connection with maxims
1 through 11 insofar as they affect your plant means that all
you are likely to get is a set of elegantly completed forms
that amount to little or nothing. Using such people to develop maintenance programs is to wander into the hazy – and
dangerous – region where delegation becomes abdication.)
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