Operator Performed Maintenance

Yesterday we wrote about the importance of operator basic care or "operator performed maintenance" (OPM). Today we hope to provide some insight into how to begin to implement a world-class effort. Any implementation will be shaped by the plants history, culture, union work rules, etc. Communication with everyone involved about the goals, and getting by-in from operators, mechanics, union leaders will lay a good foundation. The OPM effort must ensure that no safety hazards are created, training should be provided for any new skills required, should not have a negative impact on existing job requirements, should resolve any union work rule issues, and should be a team effort by all employees. With this backdrop what sort of maintenance can be assigned to operators? A starting point can be:

- Lubricating equipment; checking levels, frequency, types.
- Minor adjustments; checking and tightening parts, belts, conveyors, etc.
- Cleaning equipment.
- Minor preventive maintenance; changing filters, tightening packing, etc.
- Minor instrument calibrations.
- Preparatory work for maintenance on the following shift; draining, inerting, disassembly.
- Log sheets for unusual noises, pressures, temperatures, steam/air leaks.
- Activities that the joint maintenance-operator team develops.

The goal of an OPM program should not be a reduction in maintenance staffing. The focus should be on transitioning the operators to owner-operators, and the maintainers to maintainer-improvers.

Synchronous LLC is committed to maintaining a continuing dialogue on operational excellence and best practices for the process manufacturing industry. To pose a question, contribute a best practice, or otherwise add to the dialogue, send a note to RobBaldwin@SynchronousLLC.com . To subscribe to our weekly newsletter send your preferred email contact address to Webmaster@SynchronousLLC.com with SUBSCRIBE in the subject line.