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Japanese Path to Maintenance Excellence

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An excerpt from the audio version of the eBook "The Maintenance War - The Japanese Path To Maintenance Excellence".

This excerpt is from the Maintenance Equipment Criticality section.

Before you listen to the "How to Decide Maintenance Criticality Ranks" section, for context, first we will vie
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An excerpt from the audio version of the eBook "The Maintenance War - The Japanese Path To Maintenance Excellence".

This excerpt is from the Maintenance Equipment Criticality section.

Before you listen to the "How to Decide Maintenance Criticality Ranks" section, for context, first we will view an excerpt from the introduction part of the eBook "The Maintenance War" is in order...

"You will learn about a number of diverse topics in the next few pages. You will read about how this particular Japanese company determined its equipment and component criticality. You will learn about a new, truly effective way, of making next year’s maintenance plan. You will learn about condition monitoring the Japanese way. The Japanese are great maintenance investigators and you will be impressed when you learn how they do their failure analyses. We will also cover their psychology of maintenance – the way they think about maintenance and how they look at it. You will be astounded at their mind-set."

"The report is divided into three broad sections. Planning Maintenance shows the methods used by this Japanese chemical company to arrive at its daily work activities. Implementing Maintenance explains the methods used to arrive at which activities are required. The Maintenance WAR explains the mindset of the Japanese involved in operating and maintaining plant and equipment."
Snippet Transcripts
Yeah. How do you decide what level and type of maintenance to use on an individual item of plant and its sub assemblies? Not all equipment is equally important to your business. Some are critical to production and without them the process stops. Others are important and will eventually affect production if they cannot be returned to service in time, while other items of plant are not important at all can fail and not affect production for a very long time. As a maintainer, you want to know which equipment in your plant falls into each of those categories so you can determine your response. Furthermore, you want to know which subassemblies in each item of equipment are critical to the operation of the machine. From this information, you can decide which spares to hold on site in which to leave us outside purchases. The equipment criticality also determines what level of preventative maintenance to use, what type and amount of condition, monitoring to use and what type and amount of observation is required from the operators. You can also use it to justify online monitoring systems to protect against catastrophic failure. The Western approach to determine criticality is often to use either reliability centered maintenance or risk based maintenance to determine consequences of failure and then address the appropriate response to prevent the failure. The Japanese chemical manufacturing company I visited had a novel way of determining their equipment criticality. They based the equipment and component criticality on the knock on effect of a failure and the severity of the consequences. It is the same intention as the previously mentioned methods, but the
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