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Key Processes for a Successful PdM Program by Doug Plucknette and Ron Moore – CONNECT CONVERSATIONS

Doug Plucknette | Contributing Host, RELIABILITY CONNECT
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In this episode of CONNECT CONVERSATIONS, reliability leaders Ron Moore & Doug Plucknette discuss Key Processes for a Successful PdM Program.

Predictive Maintenance, or PdM, has been around for decades, harking back to the 60’s and 70’s, and only became practical for routine use by technicians in the late 80’s with the advent of more advanced microchips.  Unfortunately, most programs are not well implemented, or even programs.  All too often a beautiful demonstration will be performed, showing all the things you can do with (vibration, oil, infrared, ultrasound, etc.), a technician will be assigned, trained and achieve some success, UNTIL, the tech leaves, or the related problems have been “solved”, or some other reason, and the instrument ends up on a shelf, for occasional use, maybe.  We’ll be discussing the elements of a good program:

  • Application of RCM principles/data and understanding failure modes, consequences, and the PF curve
  • Instrument selection based on failure modes and criticality
  • Technician selection and training required
  • Criteria for equipment to be reviewed – routes, fault definition (Criticality and Total Cost of failure)
  • Linking findings to the planning and scheduling process, including operator findings and operations planning
  • Measuring success
  • Program quality measures/determinants
  • Use in commissioning
  • Contracting your PdM program, or not
  • Why programs fail
  • Point in time measures or continuous monitoring?
  • Before you perform your first routes, training for craftspeople, operations supervisors and operations managers is a must. (Assuming maintenance managers and supervisors have at least a level 1 understanding of the tools and how they should be applied)
  • How will we measure the success of the program? Route Compliance, Corrective Maintenance prior to failure
  • What 4 tools make up the start of a good CBM program? Airborne Ultrasound, IR Thermography, Vibration Analysis, Motor Current Analysis
  • What are the most under-utilized condition monitoring techniques? The PLC and Human Senses
  • The measure everyone seems to ignore – Total Cost of not acting

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About the Author

Doug Plucknette Contributing Host, RELIABILITY CONNECT

Doug Plucknette has been in the Field of Asset Management, Maintenance and Reliability for 38 years. In 1999 he founded Reliability Solutions Inc. As the founder of RCM Blitz™ and author of the book Reliability Centered Maintenance using RCM Blitz™, he has provided reliability training and consulting services to numerous companies around the world, large and small, including such Fortune 500 companies as Cargill, Whirlpool, Honda, Kraft-Heinz, Schlumberger, Corning, Invista, and Newmont Mining.
Doug has made key contributions to standard reliability measures for manufacturing, and reliability training programs worldwide. He has trained numerous client RCM Facilitators and performed RCM analyses on hundreds of pieces of manufacturing equipment.
Prior to his work as a consultant, Doug worked 19 years at Eastman Kodak Company in Rochester, NY in positions as a skilled tradesperson, lead person, Maintenance Supervisor, and Reliability Engineer.
Recognized as an Industry Expert, Doug has published over 50 articles, written two books, has been a featured speaker at dozens of conferences and Key Note Speaker for two Global Reliability Conferences.