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How I Applied Expertise in Maintenance Management, DevOps, Data Engineering, and Data Science to Implement a Complete Predictive Maintenance Solution with Amazon Monitron and Grafana

Pay attention to these metrics Key Performance Indicators (KPIs), are crucial for tracking maintenance performance within an organization. These metrics can range from general indicators such as downtime and overtime to specific details like pending work orders. As a maintenance manager, it is essential to apply due diligence in following up on these metrics as a basis for daily planning and stand-up meetings. This practice ensures that all pending jobs are reviewed and discussed, allowing you to identify and address any issues that might affect the prompt completion of tasks. A common practice is to review the job status with each technician during planning meetings. This aligns with the principle that “whatever is not measured cannot be monitored, and monitoring breeds commitment.” This approach is not about micromanagement but rather about obtaining daily updates from the team through standardized planning meetings to keep everyone aligned and informed. The use of a computerized maintenance management system (CMMS) has streamlined and enhanced the accuracy of this process. The focus is to get the job done and not to just close the work order electronically, as has been observed in different scenarios. Filter the work order by type or category. A universal classification is preventive maintenance (PM) and corrective maintenance or demand work order (DM) The next part of the metric is to filter the work order status. This will give details of the status of the workers: pending review, not started, in progress, overdue, on hold, etc., as the case may be. This is important to help track all pending work orders and their status. A maintenance manager must see this process as a daily routine. Another important KPI is the number of work orders completed during the week or review period . This is particularly important in keeping track of task assignments and execution by the team. With this, the performance of each of the technicians could be monitored, and the functionality of the prevailing preventive maintenance structure could be ascertained.

Harnessing Data Science for Predictive Maintenance Data science has become integral to various fields, including Industry 4.0, where it plays a crucial role in predictive maintenance—a key component of modern asset management. In the context of Industry 4.0, massive amounts of data are continuously generated and stored. This data is invaluable for predictive maintenance, which uses data science to anticipate equipment failures and optimize maintenance schedules. By leveraging advanced mathematical and computational techniques, professionals can identify the root causes of machine failures and quality deviations, minimizing downtime and financial losses. One of the most significant applications of data science in manufacturing is in predictive and preventive maintenance. This process relies on several key technologies: 1. Sensors Sensors are fundamental in providing real-time monitoring and measurement of physical conditions. They gather data on various operational parameters, enabling organizations to detect potential issues before they lead to failures. 2. Gateways Gateways play a crucial role in securely collecting sensor data and transmitting it to the cloud. This ensures that the data is available for further analysis and decision-making. 3. Condition Monitoring Condition monitoring systems track changes in physical conditions over time. Organizations can quickly detect and address anomalies by comparing real-time sensor data against predefined thresholds. 4. Alerts Real-time alerts notify stakeholders immediately when potential issues are detected, allowing for prompt intervention to prevent equipment failures or production losses. 5. Advanced Analytics Advanced analytics are employed to analyze the collected data, extracting actionable insights that help organizations make informed decisions. This capability is essential for predicting when maintenance should be performed to avoid unexpected downtime. 6. Cloud Technology Cloud technology supports the entire process by providing scalable storage, processing, and analysis capabilities. It allows organizations to access their data and analytics tools from anywhere, ensuring that maintenance decisions are timely and well-informed. #datascience #maintenance #machinelearning #industry4.0

DUE DILIGENCE IN MAINTENANCE MANAGEMENT Part one - Expectations from a Maintenance Manager. a. Work Instructions As a maintenance manager, it is crucial to provide clear and documented work instructions for maintenance technicians. Maintenance work instructions can be defined as written guidelines that specify how a maintenance task should be performed and outline the expected quality standards for the work order. The reasons for having work instructions include: Managing and Limiting Human Error: Clearly defined instructions help reduce mistakes by providing precise guidelines. Reducing Variability in Task Performance: Standardizing procedures ensures consistent performance across tasks. Ensuring Adherence to Safety Procedures: Detailed instructions promote safety by outlining necessary precautions. Maintenance work instructions are living documents subject to continuous improvement as we strive to find the most efficient and safest ways to perform tasks. They are typically drafted from OEM manuals combined with practical experience in equipment management. While OEM manuals often specify tasks to be performed at specific intervals, they usually lack detailed “how-to” procedures. Although many OEM manuals provide technical drawings of machine assemblies and subassemblies, these drawings may not be sufficient for technicians who need detailed, task-specific work instructions. For example, the maintenance plan for a mixing machine by DISONA (picture attached in comment section ) includes all necessary requirements, but it is the maintenance manager’s responsibility to extract this information and create concise, easy-to-understand work instructions. These instructions should be integrated into a computerized maintenance management system (CMMS) if available. Work instructions should be developed with the end-user (technicians) in mind and must include the following key elements: The Equipment: Clearly identify the equipment involved. The Maintenance Task: Describe the specific task to be performed. Acceptable Limits: Specify acceptable tolerances or conditions. Safety Instructions: Provide necessary safety precautions. Follow-Up Actions: Outline any subsequent steps or checks. A detailed monthly preventive maintenance procedures for the mixer is attached in the comment section . b. Training of Technicians In addition to providing detailed work instructions, it is essential to conduct on-site training for technicians. This training ensures that technicians fully understand the working principles of the machine and can execute maintenance tasks as specified in the work instructions. Training bridges the gap between theoretical knowledge and practical application, ensuring that maintenance functions are performed correctly and efficiently. Share your thoughts in the comment section.

Lessons for Maintenance Managers While breakdowns are often seen as a nightmare by production managers, the value they provide to maintenance managers is significant. Even with a strong commitment to preventive maintenance, a hard truth remains: without documented experiences of failures, maintenance personnel may not fully understand what to look for during maintenance execution. The OEM maintenance task list is invaluable, but knowing how to carry out the inspection and maintenance is an entirely different challenge. Research into the dominant root causes of failures in the manufacturing industry has shown that issues related to human error and improper methods contribute to more than 90% of total breakdowns and downtime. These problems often stem from deficiencies in the functional competencies required to perform quality maintenance across various aspects of the manufacturing system. The complexity of machines’ working principles and parts assemblies further exacerbates these issues. Theoretical knowledge from machine manuals and training illustrations, while helpful, may not be explicit enough without actual experience and detailed knowledge gained from resolving issues directly on the machine. In other words, failures offer an opportunity to understand the internal mechanisms of the machine, and the troubleshooting process validates the actual principles of operation. For this reason, a maintenance manager should be present as much as possible during breakdown resolutions. The knowledge gained from the disassembly, visualization, and reassembly of the machine should be used to create practical work instructions for technicians. Knowing what needs to be done is one thing; knowing how to do it and what to look out for while executing the maintenance task is another. https://lnkd.in/gTZtayvm

Condition monitoring

What do you know about the 3i3r Approach to Preventive Maintenance? The 3i3r Approach to Preventive Maintenance is a systematic method for conducting maintenance tasks that promotes thoroughness and consistency. This approach breaks down the maintenance process into six key steps, divided into two phases: The 3i Phase Instruction Begin by reviewing clear, detailed guidelines for the specific maintenance task. This ensures technicians understand the proper procedures, safety protocols, and equipment requirements before starting work. Inspect Conduct a comprehensive examination of the equipment or asset. This involves visual checks, operational tests, and measurements to assess the overall condition and identify potential issues. Identify Based on the inspection, pinpoint any problems, wear and tear, or areas that require attention. This step is crucial for determining what actions need to be taken in the next phase. The 3r Phase Repair Address any issues identified during the inspection. This may involve adjusting, tightening, or fixing components to restore proper functionality. Replenish Restore any consumables or materials to their required levels. This could include lubricants, fluids, or other supplies necessary for optimal equipment operation. Replace Swap out parts that are worn out, damaged, or no longer functioning as intended. This proactive replacement of components helps prevent unexpected failures and extends the equipment’s lifespan. By following this structured approach, maintenance teams can ensure that preventive maintenance tasks are performed consistently and effectively. The 3i3r method helps reduce the likelihood of equipment failures, minimizes downtime, and maximizes the longevity of assets. It also provides a clear framework for documenting maintenance activities, which is valuable for tracking equipment history and planning future maintenance schedules. https://lnkd.in/dihNA2ex

10 STEPS TO SUCCESSFUL PM IMPLEMENTATION Implementing a robust Preventive Maintenance (PM) program is crucial for ensuring the longevity and efficiency of your equipment. A well-structured PM cycle not only prevents unexpected breakdowns but also enhances overall operational efficiency. Below, we’ll walk you through a 10-step PM implementation cycle that can streamline your maintenance process, making it more efficient and effective. 1. Plan and Prioritize Work Orders The journey begins with careful planning. The coordinator or planner assesses the maintenance needs and prioritizes work orders using Hippo CMMS. This system helps organize tasks based on urgency, ensuring that critical maintenance is addressed first. 2. Prepare for Execution Once the work orders are assigned, technicians print them out and head to the shop floor. Here, they follow the 3i3R PM approach—a method designed to ensure thorough inspection, immediate intervention, and accurate reporting during the maintenance process. 3. Document Findings on the Spot As technicians carry out their tasks, they record all findings directly on the printed work order. This step is crucial for capturing real-time data about equipment condition, ensuring nothing is overlooked. 4. Update the Digital Record After completing the task, technicians update the work order in Hippo CMMS with their observations and findings. This digital record-keeping ensures that all data is centralized and easily accessible for future reference. 5. Raise Associated Work Orders for Additional Jobs Sometimes, maintenance uncovers the need for additional work. In these cases, technicians raise associated work orders within Hippo CMMS, ensuring that any follow-up tasks are documented and scheduled without delay. 6. Store Completed Work Orders Once the work is done, the technician stores the completed work order in the closed work order basket. This step signifies the transition from execution to review. 7. Review by Maintenance Engineer The Maintenance Engineer retrieves these closed work orders for a thorough review. This review often includes a visit to the shop floor to verify that the job was completed correctly and to the required standard. 8. Verify and Update Task Lists During the review, the Maintenance Engineer may identify the need to update the task list. Whether it’s refining existing tasks or adding new ones based on the latest findings, this step ensures the PM program remains relevant and up-to-date. 9. Final Documentation After the review and any necessary updates, the Maintenance Engineer files the work order in the work order history file. This historical record is invaluable for tracking maintenance trends and planning future PM activities. 10. Continuous Improvement With the work order filed, the cycle is complete—until the next scheduled maintenance. Each completed cycle contributes to a continuous improvement process, helping your team refine their approach.

#SafeInterventionDecisionTree A #SafeInterventionDecisionTree is a #structuredframework designed to guide #decisionmaking during #maintenance or #operationalinterventions, ensuring #safety and #efficiency. It helps identify #potentialrisks, #evaluate the #severityofissues, and determine #appropriateactions to #mitigatehazards. By following this decision tree below, teams can systematically #assesssituations, make #informedchoices, and implement #safetyprotocols to #protectpersonnel and #equipment, ultimately enhancing #operationalsafety and #effectiveness. https://lnkd.in/dqMRAymb