Do you provide training based on what your repair logs indicate is needed? Any good maintenance operation documents the repair work. But does anyone look at the repair documentation to spot training deficiencies? Is there anything in the system that highlights frequent failure modes or competence-related failures?
For example, five motors fail in one year. Four of them have grease in the windings. This problem will continue until you have enough qualified people to lubricate motors and only those people perform motor lubrication. It takes much less time to properly lubricate a motor than to replace a motor, so this frees up maintenance resources while lowering costs and increasing uptime.
To collect failure data in a way that makes them amenable to analyzing, provide repair techs a checklist of five failure modes plus “other” (a long list won’t work). Review this checklist every six months and update as needed.
