August 2005 - Library
August 2005 - Library
August 2005 - Library
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22<br />
A<br />
Implementing<br />
Change In A<br />
Maintenance Team<br />
- Is It Possible?<br />
BSTRACT<br />
Michael W. Killick<br />
OpEx Management Ltd (New Zealand)<br />
In today’s modern business environment, organisations are continually looking to improve the perf o rmance of their operation in<br />
o rder to remain competitive in their chosen industry. If an organisation is in the manufacturing industry they face the additional<br />
p re s s u re of outsourcing non-core business functions or, at the extreme end of outsourcing, changing from a local to overseas<br />
manufacturing operating where the plant is located in developing nations.<br />
To ensure that local manufacturing remains competitive, organisation needs to operate with high plant utilisation, high productivity<br />
(both in terms of physical resources and human resources) and cost effective expenditure. Further to this, the organisation has to<br />
have a workforce that is focused on a common goal and works together as one large effective team that is continuously improving<br />
the level of performance.<br />
However in manufacturing industry, the achievement of ‘one large effective team’ is not an easy exercise due to the (traditional)<br />
conflicting requirements of the production and maintenance management teams - production want the plant operating to produce<br />
widgets while maintenance want the plant shutdown to perform maintenance.<br />
In order to overcome this, the maintenance team needs to take the lead and break the traditional approach to asset management<br />
(the combination of production and maintenance management) and apply a total asset management focus as to how the org a n i s a t i o n<br />
manages it assets - such an approach being underpinned by the concept of Business Centred Maintenance 1 .<br />
But to achieve Business Centred Maintenance requires a radical paradigm shift in the maintenance team culture. This shift can<br />
be achieved through various means but for it to be sustainable, a clearly defined change management process must be developed<br />
and implemented.<br />
This paper will outline how the maintenance team can achieve this paradigm shift through the implementation of an effective change<br />
management process that is guided by the principles of the Change Management Cycle 2 .<br />
THE TRADITIONAL MAINTENANCE ORGANISATION<br />
World-wide maintenance practice has taken three major evolutionary steps in the last fifty years. Up until the advent of sophisticated<br />
analytical techniques, maintenance practice was largely of a reactive ‘fire fighting’ mode where machine failure was considered<br />
inevitable and the role of maintenance staff was to react quickly to limit the impact of the failure.<br />
The development of more sophisticated tools in the 1970’s, to more accurately understand the current perf o rmance and state of<br />
wear of equipment and machinery, allowed maintenance practices to evolve to the point where the dominant maintenance activity<br />
could be driven by actual machine condition. While in the last 20 years, a new kind of maintenance practice has evolved based on<br />
a comprehensive understanding of the nature of the failure and how the failure can be subsequently mitigated. These three main<br />
changes in maintenance practice are highlighted in Figure 1.<br />
During the last decade organisations have faced an increasing pressure from shareholders to improve the return on investments<br />
of manufacturing plant - to do this, organisations have to improve plant utilisation and plant productivity. As a result organisations<br />
began to recognise the importance of effective maintenance management as being essential to the core business operation. This<br />
recognition then drove the field of maintenance management to become a business focussed organisation where profitability and<br />
competitiveness became the main focus of an organisation. But the real question still remained as to how best to approach managing<br />
the maintenance team as a business.