Efficient Plant April 2020 - 24

department | on the floor
True collaboration between
an empowered operator
and maintenance can play
a major role in improved
reliability and uptime.

do some repairs" result in maintenance cost savings to
as much as 50%. Just having operators involved in regular PM checks/visual controls gets you halfway there.
Of course, the biggest benefits are the associated
improvements in uptime and throughput. However,
remember that the goal of maintenance is not to fix
things, but to make sure that they don't break in the first
place.
At what level is your operator-maintenance partnership? Following is a 1 to 10 scale, with the items being
cumulative (all previous items should be performed).
Do operators:
1. Run the equipment (or only load parts)?
2. Start and shut down the equipment?
3. Do PM rounds to monitor visual controls/aids for
possible abnormal conditions?
4. Read meters, adjust valves, look for leaks and
kinked/plugged lines?
5. Collect information and respond accordingly?
6. Receive training on the process-critical functions
and understanding of the overall impact of downtime or
problems elsewhere in the system?
7. Perform functions such as making minor adjustments and lubrication maintenance?
8. Assess their equipment from a reliability and
maintainability viewpoint to assist/perform continuous
improvement?

24

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EP2004onthefloor.indd 24

9. Contribute regularly to reliability and maintainability initiatives to improve safety, uptime, cost, and
product quality?
10. Participate as full partners with the maintenance
department to ensure uninterrupted operations?
Properly focused operator rounds can prevent many
issues with early detection and ongoing continuous
improvement by those closest to the operation. The term
"owner operator" is used with TPM to signify the operator caring about the equipment they work on or near. It's
also important that the operator views that his/her effort
is meaningful and valued. That means operator reports
are converted to work orders and feedback results in
improvements and benefits. This greatly enhances the
team culture between maintenance and operations.
The best companies view reliability and maintenance
as a seamless process i.e., no silos. They function with
operations and maintenance as a partnership, supporting a shared vision and goals to enable best return on
asset investment. EP

Based in Knoxville, Klaus M. Blache is director
of the Reliability & Maintainability Center at the
Univ. of Tennessee, and a research professor in the
College of Engineering.
Contact him at kblache@utk.edu.

APRIL 2020

3/27/20 10:19 AM

http://www.EFFICIENTPLANTMAG.COM

Efficient Plant April 2020

Table of Contents for the Digital Edition of Efficient Plant April 2020

Efficient Plant April 2020 - Cover1
Efficient Plant April 2020 - Cover2
Efficient Plant April 2020 - 1
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