City Scape

Passage from Reactive to Preventive Maintenance

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Content Description
Original date: 
Saturday, December 18, 2021

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

BoK Content Source: 
MainTrain 2022
BoK Content Type: 
Presentation Slides
Asset Management Framework Subject: 
03 Lifecycle Delivery, 3.05 Maintenance Delivery, 3.06 Reliability Engineering
Maintenance Management Framework Subject: 
01 Business & Organization Context, 1.4 Strategic Maintenance Plan, 02 Maintenance Program Mgmt, 2.0 Maintenance Program Mgmt General, 04 Tools and Tactics, 4.4 Preventive Maintenance, 06 Work Management, 6.4 Backlog Management, 6.5 Work Execution & Closeout, 07 Human Resource Management, 7.2 Education, Training & Development, 08 Material Resource Mgmt, 8.1 Materials Management, 8.2 Inventory Management, 10 Continuous Improvement, 10.3 Maintenance Management Improvements, 10.4 Maintenance Practices Improvements, 10.5 Asset Reliability Improvements
Author Title: 
Principal Consultant
Author Employer: 
Bora Consulting Inc.
Author Bio: 

Alp is the founder and principal consultant of Bora Consulting, a boutique firm focused on helping mining companies improve their asset management and maintenance challenges, and achieve operational excellence.

Alp has over 10 years of experience working on multi-million dollar projects with major companies such as Rio Tinto, Tata Steel, Vale among others as an operations and maintenance professional.

With his engineering background, he leverages his experience in business strategy and operations to help firms optimize production and achieve their business objectives.

Alp holds a Mechanical Engineering degree with a specialization in Mining Engineering from McGill University.