A three-shift plant employing 1,200 people per shift had an overburdened maintenance department. Prior to the arrival of a new plant engineer, their solution was to work faster. This meant shortcuts, and shortcuts inevitably increase the equipment failure rate.
After spending considerable time inspecting equipment and reviewing the maintenance logs, the plant engineer issued the following requirements for completing a belt replacement. Despite extra time for each repair, within a month the total time for changing belts dropped. Can you see why?
• Ensure the part number on the new belt matches the one in the work order. No generic belts.
• Bring a bucket; among other things, you will need to collect the old belt and dirt you remove from the guard.
• Bring a portable light, the correct tension gauge, and any tools indicated on the work order.
• Check the pulley; if it’s not perfect, notify the mechanical supervisor.
• Clean the guard. Replace any missing hardware.
• Take vibration readings. Put in a work request for corrective action if vibration is excessive.
• Visually inspect the flexible conduit going to the motor.
• Leave only when the area is clean.
