2022 Schedule

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Passage from Reactive to Preventive Maintenance

Presenter: Alp Bora
President & Principal Consultant, Bora Consulting Inc.
Description:
Sharing a recent mandate with a mining client where we assessed the maturity of maintenance management. The webinar will also cover the findings and our actions for improvement. Approach 1. After dozens of interviews from trades to maintenance manager, from operators to supervisors, we started to gather an understanding of the situation. 2. Then, a thorough analysis was performed on work order history, PM percentage vs total available work hours, schedule compliance and production KPIs to help pinpoint several recurring issues. 3. The analysis was concluded with on-site shadowing of supervisors and trades. We selected key dates to execute day-in-the-life-of exercises (i.e., shutdown days) to assess the quality of shutdown management and observe the execution effectiveness. Actions in partnership Tool time is a powerful metric because it helps to expose the majority of the teams’ shortcomings: engagement of the team, respect of processes, communication between departments and productivity of all the maintenance members. After the assessment and analysis, we got to work: 1. Work management process 2. Maintenance tactics review 3. Maintenance execution 4. Spare parts analysis Results With a SWAT team approach, we reduced maintenance backlog by 20%, which allowed us to focus on high criticality assets. In less than 8 weeks, we started to see a reduction in major breakdowns of equipment. We started performing root cause analysis on each breakdown and defect elimination workshops to achieve better reliability. By reducing waste related to maintenance activities in planning & execution, the team managed to transfer the work hours toward preventive tasks. The actions got translated into an improved plant availability and higher engagement
About the Presenter:

Alp has worked with multi-national companies as an operations and maintenance professional. With his engineering background, he leverages his experience in business strategy and operations to help mining companies to optimize production and achieve their business objectives. His areas of expertise are asset management, operational excellence and value creation.

Founder and president of Bora Consulting, Alp holds a bachelor’s degree in mechanical engineering with mining specialization from McGill University. Alp is a Canadian citizen residing in Chicago, USA.