CREATING A 21ST CENTURY MAINTENANCE ORGANIZATION CONFERENCE

Conference held in Mississauga on September 14, 15 & 16, 2005
Chairs: James V. Reyes-Picknell, Conscious Management Incorporated; Stephen Kenny, Atomic Energy of Canada Limited (AECL); Donald M. Barry, IBM Business Consulting Services; Cliff Williams, Coca Cola Minute Maid

CD-ROM: Over 15 hours of video presentationsl

To purchase, please contact Federated Press.

MANAGING MAINTENANCE FOR THE 21ST CENTURY

Panel: Reinventing the maintenance manager
James V. Reyes-Picknell, President, Conscious Management Incorporated and Mick O'Sullivan, Plant Manager, Goodrich Aerospace of Canada

• The new role of the maintenance manager
• How to spot leadership?
• Using self-organized teams for success
• Skills of the new maintenance manager
• Vision and mission of the maintenance manager

"Maintenance managers today are called upon to inspire their workforces, not to control them. If you get your people to work because they really want to, not just because they need to, then you are a leader."

Video: 44 minutes • Overheads

Capturing the knowledge of your aging workforce & planning for the future shortage of skilled maintenance technicians
David Crockett, CEO & President, CenTec, Inc. and Mark King, Director of Labour Relations, Michelin North America

• Maximizing capabilities through a multi-skilled program
• Defining core competencies
• Developing a long-term plan
• Defending against liabilities
• The Uniroyal Goodrich experience
• Employee and union acceptance

"Given the double whammy of a high retirement rate, combined with fewer people entering the maintenance professions, there has developed an urgent need for corporations to professionalize their human resource processes in the hiring of skilled maintenance workers."

Video: 42 minutes • Overheads

Understanding OEE for benchmarking
George Donaldson, Maintenance Manager, The Toronto Star Newspaper

• Where to start?
• Creating a template
• Developing a guide
• Benchmark results

"Overall equipment effectiveness (OEE) can significantly improve the efficiency of one's manufacturing processes by monitoring and tracking the availability, performance and quality of one's equipment."

Video: 39 minutes • Overheads

Case study: Scheduling proactive maintenance at Molson
Arkadiusz Skupien, Director of Maintenance, Molson Canada

• Gap concept: goals and benefits
• Work planning and scheduling
• Executing the work
• Follow-up procedures
• Best practices for root-cause analysis

"Molson's has shown that allowing for a production gap in the production line process, for maintenance requirements, can be 50% more effective than traditional weekend downtime windows."

Video: 45 minutes • Overheads

BEST PRACTICES IN MAINTENANCE

What drives scheduled shutdown maintenance?
Stephen Kenny, Chalk River Labs Decommissioning and Facilities Manager, Decommissioning Planning and Operations, Atomic Energy of Canada Limited (AECL)

• Best practices in scheduled shutdown maintenance
• Shutdown drivers and justification
• AECL's simplified shutdown process
• Dealing with unplanned outages
• Keys to success in the shutdown process

"It is important that shutdowns be approached in a homogeneous manner throughout the organization. Prioritization of duties, communication, and tracking of performance are all key elements for a successful shutdown"

Video: 45 minutes • Overheads

Case study: Achieving success in OPG's mobile equipment fleet maintenance program
David Liu, Production Supervisor – Maintenance, Fuel Ash Site & Services, Nanticoke Generating Station, Ontario Power Generation Inc.

• Implementation of the new PM program
• Identifying problems and finding solutions
• Total mobile fleet annual maintenance costs
• Making continuous improvements

"By carefully identifying the source of problems – parts, planning and human resources – the Nanticoke generating station was able to come up with solutions that increased fleet reliability and reduced maintenance costs."

Video: 45 minutes • Overheads

Building a world-class maintenance facility
Mick O'Sullivan, Plant Manager, Goodrich Aerospace of Canada

• Building a new maintenance management culture
• Life cycle costing assets
• Cost competitiveness in new machine implementation
• Developing a history of asset maintenance

"To build a topnotch maintenance organization demands teamwork and a proactive corporate culture. Every maintenance professional in the plant must be fully involved with the processes."

Video: 32 minutes • Overheads

Shutdown communication
Tommy Wong, Facility Director, Brookfield LePage Johnson Controls, York Central Hospital and Martina Breunig, Maintenance Coordinator, York Central Hospital

• Planning for communication
• External and internal communication strategies
• Using checklists and other communication tools
• Communicating results

"The carrying out of an efficient and safe shutdown process depends on ensuring on going communication between all persons and departments involved. This includes both internal and external communication."

Video: 28 minutes • Overheads

Using root cause analysis to improve reliability
Tony Rodriguez, Director, Pemmax Consultants

• Examples of plant productivity repetitive problems
• Typical plant productivity sporadic problems
• Objective of root cause analysis (RCA)
• RCA team set-up and CSF
• RCA methods – the PROACT system
• The 7-step process to analyzing the event data

"The utilization of a systematic methodology in finding and analyzing the root causes of equipment failures, helps to overcome ingrained attitudes towards repetitive plant problems, thereby saving money and manpower hours."

Video: 71 minutes • Overheads

Stream A: CONTROLLING MAINTENANCE COSTS

Deploying lubrication excellence to reduce downtime & operating costs
Jason Kopschinsky, Technical Consultant, Noria Reliability Solutions (NRS), Noria Corporation

• Quantifying the benefits of lubrication excellence
• Making the sale to management
• Challenges of achieving lubrication excellence
• Measuring lubrication process

"Achieving a cost effective lubrication policy is as much a part of cultural and knowledge based changes within the company, as it is one of technical skills."

Video: 57 minutes • Overheads • Paper 12 pgs. (2127 words)

Case study: Bottom line impact of reliability improvement
Randy Grant, Reliability Specialist, Ivara Corporation and Steve Broadhurst, Senior Reliability Practitioner, Domtar Espanola Mill

• Asset reliability process
• Comparison of work ID processes
• Key reliability practice
• Leveraging existing methodologies and implementing new ones
• Case study: Domtar Espanola's challenge and 3-step plan to success

"Maintenance effectiveness can be incorporated into the business strategy of the corporation in its strategy to drive profits. By implementing a business process for maintenance, the cost savings can be significant."

Video: 65 minutes • Overheads

Case study: Boosting your maintenance budget through cost-saving energy management
George Mitsopulos, Senior Manager, Energy, SNC Lavalin ProFac Inc. and Enzo Romano, Plant Engineering, Facilities Specialist – Electrical, L-3 Communications Electronic Systems Inc.

• Boosting your maintenance budget through cost-saving energy management
• Measuring and monitoring: using Web-enabled software
• Identifying and implementing energy projects
• Plant engineering approach
• Project concerns and solutions
• Long-term advantages and environmental benefits

"It is important to raise the level of energy awareness within the corporation on such matters as energy savings, maintenance cost savings, greenhouse emissions so as to ease the process of obtaining funding approval for project implementation."

Video: 54 minutes • Overheads

Stream B: APPLIED MAINTENANCE TECHNOLOGIES

The impact of change management in a major asset management or CMMS transformation project
Donald M. Barry, Associate Partner, Supply Chain Operations, IBM Business Consulting Services

• Impact of change management in CMMS/EAM projects
• Challenges maintenance organizations face today
• Benefits of improving maintenance
• Survey of 11 CMMS large implementations with a change management focus
• Example of change management steps and plans
• Critical success factors of change management

"Effective change management in a major asset management program begins with leadership and strategy from the top down, continues with tactics and measurements, which should then lead to reliability and autonomous maintenance. The benefits of such a programme are risk reduction and improved strategic positioning for the corporation."

Video: 44 minutes • Overheads

Condition-based maintenance strategies
Murray Wiseman, Vice President, Technology, Technology at Optimal Maintenance Decisions (OMDEC) Inc.

• A condition based maintenance CBM demo
• Determining risk level of maintaining an asset
• Building the decision model
• Strategy management

"The goal of predictive maintenance is to strategize maintenance policies so as to effect improvements on performance and on the bottom line."

Video: 39 minutes • Overheads • Speaker's Paper  20 pgs. (2125 words)

Using web-based tools to identify and capture opportunities to improve maintenance
Frank Godin, Region Practice Manager, EMA Canada, Inc.

• Challenges faced by Akron's water supply
• Resource loading methodology framework for continuous improvement
• Case studies illustrating impact of resource loading tool
• Benefits result from implementation of resource loading tool

"To successfully introduce a change management program, you have to clarify where to focus the process on, and then define and quantify the work practices that need to be changed The Web-based system first assesses, analyzes and redesigns, and then implements the solutions."

Video: 38 minutes • Overheads

Effective work order systems best practices
William Thrasher, Manager, Maintenance and Facility Services, Patheon Inc.

• Work order systems: characteristics
• Work order systems usage in information distribution
• Why systems fail?
• Work order implementation
• Documenting the gap and how to close it

"When a recurrent problem plagues you, the work orders will show you how often, how expensive, and how long the repair took. This information helps in several ways to track down the root cause and to identify the financial exposure. Without a work order you have to rely on the memory of the tradesman."

Video: 52 minutes • Overheads

MEASURING MAINTENANCE PROGRAMS

Using performance measures to raise the value of maintenance among senior managers
Daniel A. Lawson, Manager of Maintenance, Blount Canada Ltd.

• What does maintenance do?
• Why measure performance?
• How do we connect with senior managers?
• What makes a good indicator?

"Measuring maintenance performance is an effective way to raise the awareness of senior management as to the value of maintenance, and to its contribution to the bottom line."

Video: 33 minutes • Overheads

Measuring to manage or just measuring?
Cliff Williams, Maintenance Manager, Coca Cola Minute Maid

• The results of measuring
• The measurement hierarchy and common measures
• Recording measures
• Strategy measures and people development measure
• Measuring the measures
• KPI, targets, goals: examples

"The objective of measuring strategies and people within the organization is not measurement for measurement sake, but to help bring about change in alignment with corporate goals and culture."

Video: 53 minutes • Overheads

Case study: Enhancing maintenance through data-driven decisions
Robert H. Obey, Associate Director, Global Operations, Pfizer

• The value of a robust data-collection program
• Is your data-collection tool a friend or foe?
• What data should we be collecting and how to scrub it before use
• Data and continuous improvement
• The value of internal and external benchmarking

"Data driven decisions can best enhance the efficiency of maintenance functions provided that the applications are derived from a process driven mindset."

Video: 48 minutes • Overheads • Paper 6 pgs. (463 words)

The impact of an effective preventive maintenance program
John R. Neville, Manager of Facility Operations, Thames Valley District School Board

• Preventive maintenance (PM) defined and the reasons for it
• Periodic maintenance
• Implementation of the PM program
• The do's and don'ts in a PM program

"The purpose of a preventative maintenance program is to enhance the continuous operation of facilities without interruption. Periodic maintenance and an accurate measurement system are crucial to the success of the program."

Video: 33 minutes • Overheads

Post-mortem best practices: Things to consider in your shutdown reporting
Stewart R. Brimson, Engineering Project Management, Breacon Enterprises Inc.

• Communication: pre- and post-shutdown
• Data: finalizing administrative details
• Immediate actions: priorities
• Using post mortem analysis in a prerequisite tool

"Proper best practices in shutdown reporting involves paying strict attention to communication,( both pre and post shutdown), data input, prioritizing actions, and effecting a post-mortem analysis."

Video: 34 minutes • Overheads