Chemical Engineering May 2017 - 50

Cover Story
Rethinking Maintenance:
Transitioning to a Proactive
Approach
Larry Bouvier
and Rob
Levandoski
Fuss & O'Neill
Manufacturing
Solutions, LLC
IN BRIEF
PROACTIVE STRATEGY
ACTING TODAY
C
hemical manufacturing
plays an
essential role in
society, both economically
and in our dayto-day
lives. The economic
impact of the chemical process
industries (CPI) is indisputable,
but like any industrial
sector, it is susceptible
to the vagaries of the global
economy. That is why it is essential
for CPI manufacturers
to constantly look for ways
to operate more efficiently
and profitably.
One of the keys to achieving
optimum operations is asset
management. All too often,
our observations reveal that
the industry struggles to adequately
recognize the condition
of the equipment and infrastructure
on which they rely
every day. As a result, many
manufacturers frequently experience
lower throughput, reduced equipment
reliability, higher accident rates and
increased expenses to meet regulatory
obligations. One underlying cause is that
manufacturers take a reactive approach to
maintenance, waiting for equipment failures
or accidents to occur before taking action.
Instead, companies should be proactive,
creating integrated asset-management and
maintenance programs designed to regularly
assess and monitor equipment while also
reviewing the operator skills and workplace
conditions (Figure 1).
The problem is widespread. In the authors'
experience working with manufacturers
across various industries, only about one in
ten companies has an effective and compre50
Part
2
Deploying well-timed audits and properly training employees are among the steps companies
can take to realize maintenance strategies that are proactive rather than reactive
FIGURE 1. An effective maintenance program integrates not only a survey of
equipment performance, but also the behavior of operators and the overall workplace
conditions
hensive maintenance and equipment management
program in place to keep systems
operating efficiently and safely. The financial
implications are extraordinary: American
businesses lose more than $500 billion dollars
every year to equipment breakdowns or
inefficiencies and the inevitable loss of productivity
that comes with those breakdowns.
Proactive strategy
Many companies treat maintenance as a line
item to be minimized rather than an essential
element of the company's operations. While
skimping on maintenance may provide temporary
savings, it always winds up costing
companies much more in the end.
Having an effective maintenance and
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Chemical Engineering May 2017

Table of Contents for the Digital Edition of Chemical Engineering May 2017

Contents
Chemical Engineering May 2017 - Cover1
Chemical Engineering May 2017 - Cover2
Chemical Engineering May 2017 - Contents
Chemical Engineering May 2017 - 2
Chemical Engineering May 2017 - 3
Chemical Engineering May 2017 - 4
Chemical Engineering May 2017 - 5
Chemical Engineering May 2017 - 6
Chemical Engineering May 2017 - 7
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Chemical Engineering May 2017 - Cover3
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