Asset Management Programs vs. the Brain Drain
How can we help the exodus of today’s experienced maintenance talent pool?
by Jerry D. Cederstrom
Jeez, next month Eddie and Chuck retire; who is going to replace that knowledge? This refrain is being echoed in many U.S. plants today. Some of this critical experience can be replaced with out-sourcing of repairs and/or incorporation of an Asset Management program.
Most evaluations of Asset Management programs are determined on savings from a reduction in inventory, repair vs. purchase cost and having the proper spare available. These are all important criteria, but there are key subtle advantages in a proper program that should be considered. These advantages can help overcome the rather dramatic loss of skilled maintenance technicians in U.S. manufacturing.
There are numerous articles and studies expounding on the loss of skilled personnel. It is an industry fact - availability of experienced maintenance personnel is a serious problem. Companies are incorporating new training programs and trying to adopt apprentice programs, but the die is cast - the near term outlook is not encouraging. It is a simple fact, there are fewer and fewer with the required experience to replace the key individuals who are gone or soon to retire.
How does a Smart Asset Management Program help the Brain Drain? A system that brings the supplier repair experience to a typical “inventory” based program can reduce ineffective work hours. It is vital to effectively use the key hours for those remaining experienced personnel. It is similar to managing physical parts with an Asset Program; it is making the best possible use out of your most important ASSET - Experienced Maintenance techs. Programs like S.T.A.M.P., Smart Total Asset Management Program strive to achieve a working atmosphere where the focus is having the plant maintenance resources where they are most needed. This means handling repairs that are causing downtime vs. fixing a component level part. It also means doing smart preventative maintenance so reactive type activities are reduced.
It is a given that Asset Management Programs control repairs in a cost effective manner and provide the proper parts ready when needed. What is more important is for the program to work in conjunction with the maintenance work force so their efforts go beyond just replacement of a broken part. A smart system uses the power of specialized software and effective communication programs to analyze why the breakdown or loss of efficiency occurred. With proper day-to-day recording by a member of the Asset Management Program team the software can provide reports for review by plant personnel. Program reports become the focus for discussion in sponsored activities like: “Lunch-n-Learn” and “Continuous Improvement Meetings”. S.T.A.M.P relies on professional on-site Account Managers to bring key plant personnel together periodically to discuss and address trends observed in the program reports. The Account Managers also bring specialists from the various supplier repair laboratories to discuss trends appearing in the reports.
The history of S.T.A.M.P. programs has many examples of developing “smarter” repairs. There are many factory situations where parts/components are not suitable for the application because of improper design or hard use. Having historical failure data, repair lab feedback and good plant communication increases the effectiveness of the repair. This important information allows the program supplier to suggest different repair procedures or alternative parts to improve the component fix and lessen plant downtime. The S.T.A.M.P. supplier has “experienced” technicians with specific test stands and environmental chambers to simulate real-world conditions. This focus and specialization would not be a practical in-plant repair situation.
The philosophy of a S.T.A.M.P. type program goes beyond a cost effective ready inventory of properly repaired parts. It reinforces the plant maintenance group with an analytical evaluation of repairs so they can be reduced.
Obviously, the plant goal is equipment with minimal downtime. This becomes increasingly possible with a smart approach that brings resources to assist the maintenance personnel in making the repair as effective as possible. The tech now knows the replacement part is not just a simple replacement, but something better suited to the application.
Although simplistic and basic, it is important to pay attention to the subtle, yet vital, communication and resource sharing aspects of your plant Asset Management program. Having planned improvement meetings and open discussion “Lunch-n-Learn” type activities helps bring a critical level of experience to assist the BRAIN DRAIN.
A free CD about the S.T.A.M.P. program and repair capabilities is available from the author.
Article submitted by the author: Jerry D. Cederstrom, Business Development, AZTECNOLOGY SYSTEMS, LLC., Partnering with K+S Services, Inc., 30015 Ahern Ave., Union City, CA 94587. www.k-and-s.com / (949)378-9135 / jerrycede@aol.com
June 2007
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