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January 2016 www.coalage.com 37 m a i n t e n a n c e c o n t i n u e d Policies — Spelling it Out D epartmental Responsibilities • Each department manager will ensure compliance with the policies cover- ing the conduct of maintenance. • Each department will develop and publish procedures by which other departments may obtain their services. • Operations will be responsible for the effective utilization of maintenance s ervices. • Maintenance will be responsible for developing an effective maintenance program, educating personnel on its elements and carrying it out diligently. They will also make effective use of resources and ensure that quality work is performed. Terminology • Maintenance will publish workload definitions and appropriate terminology to ensure their understanding and proper utilization. Work Order System • The work order system will be used to request, plan, schedule, assign and control all maintenance work. At the discretion of each department manag- er, the system can be used to control work requiring effective control, resource use, cost and performance information. Preventive Maintenance (PM) • Maintenance will conduct a detection-oriented preventive maintenance (PM) program. The program will include equipment inspection, condition- monitoring, and testing to help uncover equipment deficiencies and avoid premature failure. The PM program will also provide lubrication services, cleaning, adjusting and minor component replacement to help extend equipment life. • Comprehensive predictive techniques will be integrated into the PM pro- gram to ensure modern asset management and reliability technology is ful- ly utilized. • PM will take precedence over every aspect of maintenance except bona-fide emergency work. • No major repairs will be initiated until PM services have established the exact condition of the equipment and elements of the repair have been cor- rectly identified. • The overall preventive maintenance program will be assessed annually. Assessors will ensure that it covers all equipment requiring services and that the most appropriate types of services are applied at the correct inter- vals. The performance of the PM program in reducing equipment failures and extending equipment life will be verified. • Equipment operators will perform appropriate preventive maintenance ser- vices to help ensure the reliable operation of equipment. Planning and Scheduling • Planning and scheduling will be applied to comprehensive jobs (e.g., over- hauls, major component replacements, etc.,) to ensure that work is well- organized in advance, properly scheduled and completed productively and expeditiously. • Criteria will be developed to help determine which work will be planned, and all major repairs meeting the criteria will be subjected to planning proce- dures unless an emergency repair is indicated. Information • Maintenance will develop and use information concerning the utilization of labor, the status of work, backlog, cost, and repair history to ensure effec- t ive control of its activities and related economic decisions, such as equip- ment replacement. • Minimum necessary administrative information will be developed and used. • Performance indices will be used to evaluate short-term accomplishments and long-term trends. O rganization • The maintenance workload will be measured on a regular basis to help determine the proper size and craft composition of the workforce. • The productivity of maintenance will be measured on a regular, continuing basis to monitor progress in improving the control of labor. • Every effort will be made to implement and utilize organizational and man- agement techniques like teams or Reliability Centered Maintenance (RCM) to ensure the most productive use of maintenance personnel. Setting Priorities • Maintenance will publish a priority-setting procedure that allows other departments to communicate the importance of work and maintenance to effectively allocate its resources. • The procedure will facilitate the assignment of the relative importance of jobs and the time within which the jobs should be completed. Maintenance Engineering • Maintenance/reliability engineering will be emphasized to ensure the main- tainability and reliability of equipment. • Current technology will be utilized to facilitate effective maintenance. • No equipment will be modified only with the concurrence of maintenance engineering and assurances of future reliability and ease of maintenance. • All new equipment installations will be reviewed by maintenance engineer- ing to verify work quality and to ensure their subsequent maintainability. • Standards will be developed and applied to all instances of repetitive peri- odic major maintenance like major component replacements. • The most effective predictive techniques will be used to supplement condi- tion-monitoring carried out as part of the preventive maintenance program. Material Control • Established procedures for purchasing and the withdrawal or return of stocked materials will be strictly adhered to by all plant personnel. • Parts will not be removed from any unit of equipment and used to restore another unit to operating condition without explicit authorization from the maintenance manager. • Maintenance will return unused stock materials to the warehouse. Maintenance will not attempt to store such materials. Nonmaintenance Work • Engineering, operations and maintenance are jointly responsible for ensur- ing that all nonmaintenance projects (construction, modification, equip- ment installation etc.,) are necessary, feasible, properly engineered and correctly funded before work commences. • Maintenance is authorized to perform project work such as: construction, modification, equipment installation and relocation only when the mainte- nance workload permits. Otherwise, contractor support will be obtained subject to the current labor agreement. • Equipment modifications will be reviewed to determine their necessity, fea- sibility and correct funding prior to the work being assigned to mainte- nance. All such work will be reviewed by maintenance engineering before work commences.