
Here are the 5 maintenance foundations, which we can envision as the foundation of a building. If the foundation is not robust, the entire structure is at risk of collapsing.
The first and most important foundation for a factory is the equipment system or assets structure of that factory. We cannot effectively perform maintenance and any activity without a detailed understanding of the factory's asset structure.
The purpose of this classification is determining the importance/priority of each equipment so that we can determine a maintenance plan, buy spare parts as well as prepare maintenance skills accordingly.
How to apply this foundation practically and successfully?
Work order is the maintenance activity, it can be reactive maintenance, preventive maintenance, predictive maintenance or maintenance project. And it is not stopped there.
How do we manage these activities to get a high maintenance performance?
In order to have a good management, we need to define correct type of work order.
How do we classify work order in practical way?
We cannot have a good maintenance performance if we have a poor technical store or lack of spare part.
How do we manage in practical way?
All of us don’t want the repeated issue, right? So we must solve the root cause.
The objective of breakdown analysis is eliminating rootcause of breakdown.
Which tools will be used to find and solve the rootcause?
Who fixes the machine issue? That is maintenance technician and engineer.
If they have limited competency, how can they fix the machine?
How do we develop their technical competency in practical way?
How do we visualize each technician and whole team competency?
How do we implement a technical development program?
Hello everyone, I'm Eric Dao, I bring several years of experience in maintenance engineering, fortunate to work in environments with excellent maintenance foundations. This has allowed me to accumulate a robust maintenance foundations, of which I am extremely proud and have full confidence in.
The maintenance foundations includes fundamental maintenance principles, it is core methodology. Anyone aiming for success in maintenance must thoroughly understand and adhere to these principles.
This training encapsulates the essence of the maintenance foundations that I've learned, applied, and compared across various companies. To me, it is invaluable, and I wish to share these insights with those fortunate enough to encounter them.
I confirm that this is the most practical and realistic lecture on maintenance foundation across all platforms.
Reflecting on my experience, I have not change many companies. I have spent time to fully experience the maintenance systems of each manufacturing plant. I have worked for an international food and beverage company and later for an electronic equipment manufacturing company. I believe my maintenance foundations are universally applicable and definitely brings substantial and tangible benefits.
To prove my claims, here are some key performance indicators (KPIs) that improved after implementing the maintenance foundations:
1. Machine downtime significantly reduced by over 25% in the first 3 months, followed by a 50% reduction in 6 months. Mean Time Between Failures (MTBF) increased by over 50% from 24.5 hours to 51 hours. Note: These figures may vary depending on the industry and machine conditions.
2. Overall Equipment Efficiency (OEE), a measure of machine performance, increased by at least 7%, reaching approximately 90% after 6 months.
3. Maintenance costs reduced by approximately 10% annually.
Lastly, and importantly for us maintenance engineers, improved peace of mind allows for restful nights and days off.
With my experience and maintenance principles in mind, if existing maintenance foundations are not implemented effectively, advanced maintenance methods such as Total Productive Maintenance (TPM) or Reliability-Centered Maintenance (RCM) should not be applied.
Enroll and increase your maintenance/machine performance now!