You may be asking yourself, "How am I going to pull this all together?" A few statistics may help to justify or explain the benefits of a robust reliability program. The time associated with repairs can be reduced by as much as 50% because now they can be planned and scheduled. MRO inventory can be decreased by as much as 50%, because you no longer need one of everything. Instead, rely on the results of PdM technologies to order parts for repairs. "Is this significant? One of the Big Three automakers estimates that $500 of the purchase price of every vehicle sold can be attributed to MRO inventory!" Unexpected failures and maintenance costs can also be reduced by as much as 50% by developing a program exercising maintenance and reliability best practices. Our clients are reporting a positive effect on their companies P & L as a result of their reliability efforts.Testing procedures need to be developed and within these procedures acceptable alarm limits and safety protocol defined. Personnel training cannot be overemphasized. Written practices clearly defining required levels of certification/qualification for PdM technicians must be established. Reporting results for all levels within the facility is extremely important. Clear and precise reports identifying anomalies and provided repair recommendations for the skilled craft are a must for successful repair. Correlation of the results of all applicable inspection technologies for an asset is valuable, so management can make informed decisions about the timing of a repair. The results of each technology should be combined to provide an accurate picture of the health of the facility.In summary, we must identify what PdM technologies will be applied to which assets or equipment. The next step is to decide who is going to conduct these inspections: in-house personnel, contract personnel or a hybrid program. Next, apply the appropriate technologies to the right assets at the correct frequency. Integrate the results of all applicable technologies to support repair recommendations. Use this information to generate prioritized work orders that are planned and scheduled. Complete these repairs and re-qualify or validate the repairs. Use root cause techniques when appropriate to eliminate future defects. Then measure the success of the reliability program using one or more metrics.
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