The dream of every maintenance area is to become a world class organization, a maintenance where things are done at an optimal level and without waste.
World class maintenance (WCM) is based on anticipating the future and its objective is to convert all types of repairs or interventions into planned activities that prevent failures at all costs.
The orientation of maintenance management towards world class requires a change of attitude and culture in the organization. Implementing this tactic requires a high level of prevention and planning; supported by a maintenance information management system (specialized CMMS maintenance software: SAP, Infomante, etc). With which it addresses previously set goals, doing everything that needs to be done in the right way with the highest degree of scientific depth.
Objectives of the WCM
The objectives that world class maintenance has, we can list them in the following list:
- Quality and profitability of the products.
- Achievement of required production.
- Maximum reliability.
- Excellence in core processes.
- Maximum environmental protection.
- Maximum personal safety.
- Motivation and personal and customer satisfaction.
In world-class maintenance, great emphasis is placed on continuous improvement in all aspects of production. Such emphasis is motivated from the top management, being this the key for a great motivation at all levels.
World Class Maintenance Management
The fundamental steps to implement the world class tactic are: planning, prevention, scheduling, anticipation, reliability, analysis of production losses and spare parts.
The change of attitude and culture towards the customer, usually in the production area, is decisive. All of the above must be supported by a computerized information system.
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Some of the basic aspects to be taken into account are:
- The results of the WCM are not immediate, it must be taken into account that it is a long term tactic.
- The systems that generate structural, cultural and organizational change in a company last longer; and require more training of the employees.
- There must be a high commitment from all parties involved in the implementation process. It should not be felt as an obligation but rather as a motivation.
Multinational companies are the ones called to implement WCM tactics. Additionally, they are based on international laws such as SAE, ISO, DIN, British Standard. It can also be applied in companies that export products or services that must be adapted to local standards where they are sold..
World Class Maintenance Standards
These are the 10 practices that underpin a world-class maintenance system:
Team building: When the company’s organization focuses on interdisciplinary teams, it allows for a more comprehensive analysis of processes and therefore, find the best solutions and improvements.
Integration with material and/or service suppliers: Allows spare parts inventories to be managed by suppliers, so that they deliver the necessary quantity of spare parts in the established time. In this way, costs for old or obsolete inventories will be reduced.
Productivity-oriented contractors: All work contracted must have a clear planning, where the scope, time and costs are defined. In addition, contractors should be treated as strategic partners, which are encouraged if they contribute to improving production.
Support and vision of the management: The high management must be highly involved in the work of the different work teams, always supporting and giving tools for the continuous improvement. It must create training and incentive programs for the different members of the work teams.
Proactive planning and programming: The planning and programming are vital for a world class maintenance system, these processes must be organized and methodical, allowing short, medium and long term activities. In this way it will be possible to maximize the effectiveness/efficiency, of the manpower, in order to increase the availability of the equipment and to improve the quality and the quantity of produced elements.
Processes for continuous improvement: There is an intense and constant search to improve activities and processes. Such improvements must be promoted and publicly recognized by the management; in such a way that it becomes a business culture.
Disciplined management for the acquisition of materials: Process of standardization of spare parts and materials; in such a way that they can be homologated and better acquisition costs can be found. Also, to allow better negotiations and delivery times.
Systems integration: The data processing systems must be standardized for the entire organization, which will allow better communication and less time for decision making between different areas.
Disciplined management of maintenance stops: Maintenance stops should have an emphasis similar to the management of a project. With clear schedules, sufficient planning to avoid as much as possible unforeseen events. Internal personnel and contractors must be prepared in all aspects of physical and environmental safety, in addition to their own work activities.
Production based on reliability: Specialized groups of maintenance engineers are established, which must apply predictive maintenance techniques, in such a way that they allow to know the state of all the equipment and to be able to anticipate a premature or sudden failure.
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