Poor maintenance habits will destroy your machines, increase downtime, increase repair and labor costs and delay the much-needed production time. Most companies need intervention, to save their machines and increase uptime, a change in outlook and maintenance program will improve the dynamics of their program.
The main goal for this change is to increase Overall Equipment Effectiveness (OEE). According to Machinery Lubrication, OEE is the standard for measuring manufacturing productivity and the efficiency of a manufacturer’s operation. Technicians must document all maintenance actions according to this maintenance process.
Signs of a Bad Maintenance Culture
Maintenance breakdowns closely connect to a poor maintenance culture. Maintenance personnel become demotivated when they constantly deal with mechanical failures. When failures occur frequently, plant equipment begins to dictate the work schedule instead of the maintenance team controlling it.
Organizations can seek support from external experts to strengthen and improve their maintenance programs.
Neglecting Periodic Maintenance
Effective maintenance requires focus and attention. When motivation and discipline decline, personnel may consciously overlook scheduled tasks.
A motivated and healthy maintenance team increases equipment uptime and overall productivity.
Prioritizing Pay Over Machine Reliability
In some organizations, personnel prioritize overtime pay over machine reliability. This behavior harms both work culture and operational quality.
To prevent this issue, companies should offer structured benefits or performance-based incentives that boost employee morale and reinforce reliability-focused outcomes.
Solutions for Bad Machine Maintenance Culture
Machine reliability is a science that starts at the top and moves down through a plant’s organization. Machinery does not simply fail. Personnel who lack proper training and experience in correct procedures cannot prevent these errors. A positive work culture changes behavior and promotes dependability. Management and leadership shape and continuously improve an organization’s culture. Organizations can change a poor maintenance culture. Although this transformation may create difficulty and confusion, teams can achieve it. However, management must commit to providing the necessary parameters and resources to make this change effective.
The management widely influences group behavior and culture through team building, engaged team members, empowerment, communication, goal setting, mission and vision building, and a lot more. With this in mind, here are the solutions for Bad Machine Maintenance Culture according to Machinery Lubrication:
1. Right Seat for the Right Person
We’ve all heard that a company’s most valuable asset is its people. This can only be true when we hire the right person for the right position. The right person is aligned with your company’s core values and vision while being in the right position means having the competencies that are required for that position. Certain personnel that are incompetent or mismatched might pose significant operational and safety concerns rather than being productive assets. To create a successful maintenance culture, choose, nurture, and motivate the right individuals.
2. Procedure-based Maintenance
According to Machinery Lubrication, procedure-based maintenance serves to address key issues when performing maintenance activities. It reduces the variation that occurs when personnel is conducting the same work. Procedure-based maintenance also helps in minimizing the chances of mistakes. There are factors that can increase the likelihood of error. These are human sensory aspects, psychological factors, and physiological factors.
System-based maintenance is a combination of procedures created by industry professionals. These procedures improve a program by using a feedback cycle. The result of using system-based maintenance is the most highly efficient, effective, and honest work output.
Proper procedures can decrease the likelihood of maintenance errors. Following a system-based guideline for your program will lead to an effective and efficient maintenance program.
3. The Tools
A lot of new technology has entered the area of lubrication and machine maintenance in the Fourth Industrial Revolution. Many of the tools used in the past should be improved. The maintenance tools of today should be modernized and upgraded to cater to more than just repairs and corrections. It should also include instruments and equipment for inspecting and controlling situations that might cause failure or are early signs of failure. Inspection tools, condition monitoring equipment, contamination control devices, and other items are among them.
Providing your personnel with proper resources and manpower can increase productivity and work satisfaction. Giving sufficient support to your maintenance team will promote harmony and balance in your maintenance program.