Don't Forget the EPA 608 Requirement

When a law has been on the books for so long, it's possible for it to be taken for granted, or even unknown to new maintenance managers. Since the mid-1980's, the government of the United States has required that all persons who open a system or container holding a controlled refrigerant must be certified.

Persons who work on stationary equipment or use refrigerant designed for these systems can become certified by passing a proctored EPA Section 608 examination. The most reputable HVAC training providers often provide this proctored testing for no or little charge in conjunction with regular maintenance training.

Candidates for this test can be certified in any of the three equipment categories below, plus Universal.

Type I - A Type I technician primarily works on small appliances such as domestic refrigerators, window air conditioners, PTAC's and vending machines.

Type II - Primarily works on equipment using a high pressure refrigerant such as HCFC-22. The equipment includes residential air conditioners and heat pumps, supermarket refrigeration and process refrigeration.

Type III - Primarily works on equipment using a low pressure refrigerant such as HCFC-123 or CFC-11. The units are primarily chillers.

Universal - Any candidate passing all three of these EPA types is certified as UNIVERSAL.

To pass any EPA type, the candidate must pass a CORE section, plus the desired Technician section. The test is four sections (CORE, I, II, III) of 25 multiple choice questions each. All must be passed to achieve UNIVERSAL. Each section is graded separately and a passing score is at least 70%.

No one would say this is an easy test. Study and preparation are required. And, again, a reputable HVAC course training company will often provide a study guide for the test upon enrollment. Require that from your trainer, and you'll have a certified team!

When Training Enters the Safety Equation

Doing things right is often the most cost efficient and safest way to go through life. Is there really any need for near daily workplace accidents? Is there really any need for expensive non-compliance fines? Is there really any good reason to avoid standards for equipment installation and use?

Too many injuries, too many deaths, too many fines, too many shortcuts by managers. And, that costs everybody more in the long run.

Some very basic training can go a long ways to helping out, also. At a low per person costs, knowledge is incredibly valuable. What, for instance, should every facility employee know about electrical safety? OSHA has an idea, and it is all spelled out by NFPA 70E and OSHA CFR 1910.331-335. A simple electrical safety training course based on that, helps fulfill the employer's obligation.

Electrical Safety Training should be designed to save lives and prevent injuries, as well as prevent damage to plants, buildings and equipment. Trainees need and can acquire an immense respect for the power of electricity. They need to be trained on personal safety for working on or around electrical systems and equipment, how to use proper materials and procedures working...and the potential consequences for themselves or others if they don't.

If you are considering training for yourself, or your team, be sure the course covers the following, at minimum:
How to identify electrical hazards
Definitions of "qualified" and "unqualified" electrical workers
Safe approach distances to exposed electrical conductors
Improvements in PPE
"Hot Work" rules
Working rules in wet spaces
Lockout/Tagout
Safety requirements for installations
Damage potential for people and equipment
How OSHA rules apply to the workplace
And, all about OSHA penalties and compliance

It just makes sense. And, it's the Professional way.

If I Ran a Plant...

I would audit it. I would audit the operations, the personnel, the business climate, the business forecast, the hiring forecast, or even the shutdown schedule. And, at the very base of every one of those audit items, I would have a check-off box for training.

Because, if I don't have a workforce trained to do their jobs in a safe, productive and efficient way, I should close the doors. Many plants are doing just that now. Shutting their doors. For all types of reasons. And, even in that process, equipment and facilities left un-maintained are of little or no value, either for salvage or re-use later.

Because, if I don't have a workforce trained well for their tasks, I can't run an efficient operation. And, I can be selfish. If I can't run this thing well, why should anyone want me to run anything? But, everybody on the team benefits when the machine runs right.

Because, if I need to hire new people, I don't have time to wait for them to "get it." We need help now to keep this operation in form. Bring me trained people...or give me a way to get them trained...quickly and economically. Training is a faith...and great plant managers put their faith in training. Source it in, or source it out. But, source it!

Call an expert in facility maintenance training today! Here's one: 303-718-1365!

You Don't Need this Information...

...as a Maintenance Pro reading your own blog. But, amazingly, many Maintenance Pros don't always have the luxury of hiring technicians already trained, already familiar with tools of the trade. One customer of American Trainco was contracting for Electrical Instrumentation training for his staff. But, he needed some very basic information before that. Here's an abbreviated outline for a course dealing with hand tool safety. Contact this blog for further content. It could save your day!

Craft Training Related to the Safe use of Hand Tools


Hand Tool Safety:

1. Introduction and Goals
a. Course Objectives.
b. Fundamental Safety Philosophies.
c. OSHA Regulations covering hand tools
d. Many Accidents Involve Hand Tools
8% of all compensable injuries each year
500,000 people injure their hands, wrists or fingers annually
One out of four "on-the-job" accidents involve hands, wrists, or fingers
e. Examples of hand tool injury and some probable causes
f. The Process of Hazard Recognition
2. Dress Codes
a. Your company’s dress codes and PPE requirements
b. Common Dress Code Requirements
3. Basic Rules for Hand Tool Safety
a. General Safety Precautions
b. Sharp Tool Safety
c. Gripping Tool Safety
d. Impact Tool Safety
e. Leverage Tool Safety
4. Hand tool safety videos and discussion
5. Introduction to Electrical Power Tool Safety (as time permits)
a. Electrical Hazards
b. Cord, Plug, and Cord Set Safety
c. Ground Fault Circuit Interrupter Requirements
6. Final discussion related to Hand Tool Safety
7. Question and Answer Session
8. Optional Written Test

Training is the surest route to Maintenance Proship!

A Plant Maintenance Job Board Worth Checking

Go here to find a comprehensive and up-to-date listing of facility maintenance jobs. This site is managed by the Plant Maintenance Resource Center. And, as a Maintenance Pro, you will also need to know where best to look for training in maintenance subjects for yourself or your team. That's here. Good Hunting!

Time to Get Back to Training!

Maintenance pros know that the best hedge against downtime is a well-trained workforce. But, that presents its own problems. Management wants everyone to be on the same page in an efficient operation. Companies that are large enough may have the luxury of having standard company-wide training programs or internal training resources. Most do not.

There are seminars held in many cities. More cities do not have seminars. On-line training is available in some subjects, but certainly not in all pertinent maintenance areas. And, frankly, most public training is just that…public and generic.

Six Solid Reasons to Bring Specialized Maintenance Training to the Plant

Management needs to listen to Maintenance when it comes to selling the value of on-location training. And, Maintenance needs to be armed with the selling points when on-location training is considered.

First, a training supplier should endeavor to find out specifically what matters to the facility, the skill levels being dealt with, specific equipment of concern and the training outcome expected.

Secondly, with on-location training, an infinite number of subjects exist or can be created. Maintenance may think that some electrical troubleshooting is needed, when the real need is for preventive maintenance.

Third, maintenance should expect an instructor to get his hands dirty with real life walk-thru and hands-on training exercises, on the equipment at the facility.
Fourth, having multiple technicians needing training can be an opportunity to get “everyone on the same page” as mentioned. Class sizes are generally flexible with hands-on sessions best around 15 people and lecture subjects good for larger groups. Your trainer should make those recommendations.

It is never easy to get an entire crew together. Vacations, sick days, shifts. When the training comes to a facility, though, timing is up to the customer. Even the graveyard if necessary! Or, that necessary wait until downtime or August.

And, lastly, the cost. Management may balk at a price tag…until they realize that training like this, besides the above benefits, usually works out to be far less than a per person cost for seminars, travel, time away, etc.

As the economy ramps back up, worker training and efficiency need to keep pace.

Everything You Ever Wanted to Know About Troubleshooting!

Poking around on the Internet led us to an incredible web-site...all about troubleshooting. Steve Litt has maintained this site for a number of years. His technical background lends itself well to any troubleshooting task. Whether it's your building electrical system, the HVAC plant, or your home computer, Steve lays down an awful lot of common sense.

Go here to read and learn about the "Common Troubleshooting Myths." They will then lead you to the always applicable "10 Step Universal Troubleshooting Process." This is one fascinating web-site. Enjoy it!

And, by the way, thinking of Electrical Troubleshooting, American Trainco has a great solution. Check out this course for seminar sign-up, or to arrange this training at your facility. Thousands have!

How to Talk Really Smart About Electricity!

Having once worked for a character who claimed to have "invented" ultra-violet radiation, I always appreciate the chance to set people right. That's why this book looked of interest. You can amaze your friends with what you know about Electricity, by reading the History of Electricity.

And, what better way to augment your new knowledge by taking a course from American Trainco in Basic Electricity for the Non-Electrician. That will give you the knowledge to work confidently and safely at your facility. And, you'll know the history!

Boiler Operation Safety Poster Here!

Contact American Trainco for a copy of this Boiler Operator Safety Poster. Or call, 1-877-97-TRAIN.

Common Sense Saves Energy Dollars with Facility Air Conditioning

Seasonal Energy Efficiency Ratio (SEER)

As air conditioning equipment nears the end of its useful life, building owners and engineers are faced with the task of specifying and purchasing new, energy efficient equipment. An understanding of the United States Department of Energy’s (USDOE) Seasonal Energy Efficiency Ratio is necessary if the correct choices are to be made.

The Seasonal Energy Efficiency Ratio (SEER) rates each model of air conditioning equipment based on the amount of energy consumed while providing a specific amount of cooling. The SEER is an improvement of the EER (Energy Efficiency Ratio) used in the past, with the new method measuring the energy use over a wide range of operating conditions.

The SEER is calculated by using the old EER and including a part-load factor. The resulting number, ranging from a low below 9.0 to a high of over 13.0, advises the purchaser of the comparable cost of operation between competing models. The higher the number, the more efficient the unit.

USDOE regulations require an increase in the SEER rating of equipment manufactured after January 2006.

According to USDOE estimates, a 10-ton high-efficiency rooftop unit meeting the new standard of 13.0, compared to a currently installed standard unit with a SEER of 8.9, would save the owner $1,950 over the anticipated 15-year life of the unit. This calculation is based on relative purchase costs of the two units and energy consumption based on a national average of $0.08/kWh.

More HVAC Help from our Expert...Gary Xavier. Coil Cleaning Procedures to Keep Your Facility Air Conditioning in Form

Trained building maintenance personnel can easily create a preventive maintenance procedure for the coils on each unit in the facility. Every coil should be monitored on a regular basis, and a cleaning frequency determined and added to the scheduled preventive maintenance tasks.

Cleaning of evaporator coils must be performed while keeping in mind that anything on the coil can enter the building air stream. Care must be taken to use only products that are specifically labeled for evaporator and/or chilled water coil cleaning. The use of general, multi-purpose cleaners may result in residue on the coil that attracts dirt, as well as contamination of the building air stream with hazardous, or simply annoying, fumes. Air conditioning and refrigeration suppliers typically carry a complete selection of coil cleaning products, and should be consulted for recommendations. And, there is a lot of information here.

Evaporator coils can often be cleaned by shutting off the fan and simply spraying the coil with the selected cleaning solution. Most evaporator coil cleaning products are designed to be rinsed off by the condensate formed during the unit’s operation, thus requiring no rinsing by the technician. While the unit is shut down, the filter should be cleaned or changed, and the condensate drain pan and drain inspected and cleaned if necessary.

For condenser coils, the cleaning solution chosen should be matched to the contaminants on the coil. Cleaning compounds are available in both acid and base formulations, serving different purposes. Acidic (low pH) products are generally recommended only if corrosion deposits need to be removed; while basic (high pH) cleaners are used for removing grease and most types of fouling.

Regardless of the cleaner chosen, strict adherence to the labeled directions is critical, including following the recommended dilution guidelines. Maintenance personnel must also be aware of the hazards of handling and use of all chemical products, and follow the manufacturer’s guidelines for protective equipment. Consult the product Material Safety Data Sheet (MSDS) before use.

Condenser coils should be cool before the cleaning procedure is started. Using the proper cleaning compound, soak the coil with solution while making sure that the cleaner penetrates the entire depth of the coil. After allowing time for the solution to loosen the soil, rinse the coil with water, rinsing from the back to the front if possible.

High pressure water may be used as long as the water does not bend the fins on the coil or is aimed directly on motors and electrical connections. If necessary, the motor can be covered with plastic prior to cleaning.

Once the cleaning solution has been completely rinsed away, a fin comb should be used to straighten any bent fins on the coil, and the unit returned to operation.

Another in Our Spring Air Conditioning Series...Evaporator Coils & Indoor Air Quality

In addition to increased operating costs incurred as a result of dirty coils, evaporator coils (as well as chilled water coils) are placed in the building air stream. Thus, any contaminants on the coil or in the condensate pan beneath the coil may become airborne, affecting the quality of the air in the occupied spaces.

In addition to changing the filters and cleaning the evaporator coil, care should be taken to ensure there is no growth of bacteria, mold, or fungus in the condensate pan. Condensate pans, because of the incidence of standing water, are prone to this growth. Maintenance procedures should include routine cleaning of the condensate pan and drain, and treatment, if necessary, with an antimicrobial agent. Pan treatments are available in tablet form for ease of application.

Legionellosis, commonly known as Legionnaire’s Disease, has been found in evaporator and chilled water condensate pans. This disease, which can be fatal to those with impaired respiratory function, is a concern of all building owners and engineers. Further information on the source and prevention of this serious problem can be obtained from ASHRAE.

Next, we'll discuss coil cleaning procedures.

Another in Our Spring Air Conditioning Series...

Cleaning Coils Doesn't Cost - It Pays!

Air conditioning and refrigeration coils must be clean in order to transfer heat as designed; dirty coils result in running a system longer and harder to accomplish the same amount of cooling.

Longer system running times obviously result in higher operating costs. In addition, as the system works harder the energy consumption increases, as does the wear on the compressor. This additional work appears as an increase in compressor discharge (head) pressure, which is detrimental to the unit’s operating efficiency. Keeping coils clean will result in overall energy savings, better performance, and longer equipment life.

The function of the coil, either evaporator or condenser, is to transfer heat. As the air moves across the coil, heat from the air inside the conditioned space is given up to the evaporator coil; and heat from the condenser coil is given up to the outside air around the condenser. Any material that insulates the coil surface, such as dirt, dust, lint, grease, leaves, and cottonwood seeds or other pollen reduces the rate of heat transfer and increases the operating cost of the unit.

Manufacturer’s studies suggest that dirty coils can increase energy consumption by as much as 35 – 40%.

Considering the cost of electricity at a nationwide average of approximately $0.08/kWh, and air conditioner operation based on average annual use, the increased energy cost for a 10 ton rooftop unit with dirty coils could exceed $ 350.00 per year.

System cooling capacity also decreases as coils become dirty. The coil is designed to allow a relatively high amount of heat transfer, which decreases as insulating dirt adheres itself to the coil. As this fouling occurs, system capacity may fall below what is required to cool the space.

For example, a dirty condenser coil on a rooftop unit may lower the system’s cooling capacity by as much as 30%, thus a 10 ton unit would have only 7 tons of cooling capacity. This capacity loss affects building occupants when they need the cooling most, that is, on the hottest days.

A cooling system’s life expectancy is shortened by increased pressure and temperature in the compressor, which is a direct result of a lack of coil maintenance. If the unit’s compressor has to work harder, as it does when pressures and temperatures get higher, the potential for chemical breakdown of the lubricating oil increases. As the oil degrades, loss of lubrication causes increased equipment wear, leading to premature compressor failure.

By comparison, cleaning of the unit’s condenser coil, a process taking no more than 1 - 2 hours and requiring very little cleaning material, may cost the building owner up to $50.00 per unit for labor and materials. The net savings thus amount to approximately $300.00, or $30.00 per ton of capacity. This savings will vary, of course, based on factors such as the unit size and type, coil condition, energy cost per kWh, and hours of operation per cooling season.

Air Conditioning: Common Sense Saves Energy Dollars

In keeping with our theme of saving money and managing in the economic re-set, our friend Gary Xavier weighs in with some timely advice on Air Conditioning. We'll have a few more of these topics over the next couple of weeks, just in time for cooling system seasonal maintenance.

Building owners and managers often hire a service contractor to perform repairs and maintenance on their air conditioning and refrigeration systems. While this is a viable option for buildings where the maintenance department is not equipped to fully service their cooling equipment, there are preventive maintenance items that can often be addressed in-house, which lead to better system performance, lower energy consumption, and more reliable service with fewer breakdowns – all resulting in cost savings to the building owner.

Filters, Filters, Filters

If a system has a filter, the filter needs routine attention. Air conditioning (comfort cooling) systems use filters to provide a modicum of cleaning to the air supply, and also to keep the evaporator coil form becoming loaded with contaminants carried in the air stream. Refrigeration systems most generally do not use filtered evaporator coils.

The filter’s job is to catch particulate matter and hold it, while still allowing air to pass through. As the filter holds more and more debris, however, the air flow is reduced, often to a point of virtual non-existence. Many air conditioning system problems can be traced to a dirty filter. As the filter plugs up, the lack of air flow reduces the amount of cooling occurring, resulting in a lowering of the efficiency of the unit. In addition, the unit must run longer to accomplish the task of cooling the conditioned space to the desired temperature, which it often cannot attain.

Dirty filters thus result in higher operating costs and more frequent system failures, both costing the building owner money.

Filter maintenance can often be performed by building maintenance staff even in situations where an outside contractor is used for system repair. Following the manufacturer’s specifications for filter type and replacement frequencies is important, as is establishing a reliable, consistent method of determining when each filter should be cleaned or replaced.

According to ASHRAE (American Society of Heating, Refrigerating, and Air-Conditioning Engineers, Inc.) standards, viscous impingement filters - the type commonly used in heating and cooling systems – should be changed when the operating resistance through the filter reaches 0.5 inches of water column.

Air-handlers are often equipped with magnehelic gauges to measure the drop in pressure through the filter, allowing the service person to simply read the gauge on a regular basis, and replace the filter when the pressure drop exceeds the recommended limit. Smaller systems, however, such as rooftop units and room air conditioners have no such mechanism, leaving the service person to decide if a filter change is necessary.

Small system filters are often changed on frequency alone, such as every 30 days; or on their appearance to the technician during routine maintenance. Most equipment manufacturers can offer specific guidelines for their systems, and filter distributors can often be of assistance in setting up a preventive maintenance schedule.

And, more on Training...Ideas for Stretching the Training Budget

1. Outsource Your Training – Firms that outsource training cut their training costs, increase the number of courses offered to employees, and increase the number of employees trained. ASTD reports one memberc organization saved more than $360,000 by simply outsourcing.6 Nell Nicholas, a HelmsBriscoe regional director who serves the New England area says seminars in particular are “quick and inexpensive and it streamlines the ability for employees to do mulit-tasking. Outsourcing is a great way to go.”
2. Open Enrollment Seminars – The cost of program development, instructors and equipment has already been absorbed. This is the cheapest alternative for a “quick fix” without giving up high quality in most cases.
3. Ask for Discounts – Volume discounts for multiple seminar attendees are sometimes available by simply asking your vendor.
4. On-Site Training - Bringing an outside training program to your facility gives you more bang for the buck. Per student cost is less expensive than open enrollment seminars. The heavy costs of program development and internal salaries are avoided. Equipment-specific, need-specific or otherwise customized training is frequently made possible. More topics or disciplines are available at a lower cost than developing multiple internal programs on your own.
5. Cross Training – It is difficult to take an irresponsible person and make him responsible. It is easier to take a responsible person and teach him to do more and different things. Cut the fat and get the most out of your best employees by cross-training them.
6. Train the Trainer- Send someone to a training program who can bring it back and train others. The transfer will most likely be less than a direct transfer from a seasoned instructor specializing in training workers, but much of the knowledge can still be transferred. In some cases, the vendor may even be willing to sell the curriculum to assist you.
7. Get Help from Equipment Operators – Hold mini-training sessions or bring training on site to teach your operators and other employees to identify, or even troubleshoot and fix the simplest problems on their own. Whenever you can avoid getting maintenance staff involved, you save time and money.
8. Tuition Reimbursement - 89% of employees have access to reimbursed tuition programs, but only 12% take advantage of it. Encourage your employees to use the benefits they have.
And, other Ways to Stretch the Budget - Intra-company email discussions - Peer-to-peer coaching - “Fingertip” knowledge (e.g., Internet) - Join a Social Network (work specific blogs, chat rooms, Facebook) - Job Rotation - Knowledge Bases (searchable reference materials) - Memberships in professional trade associations - Subscribe to technical magazines and newsletters - Set up “self-learning” stations in your facility - Informal mentoring - Open agenda meetings to discuss the day’s or week’s work.

Third in Our Series: Training as a Solution for Tight Budgets

Training is a proactive solution to a reactive problem. Knowledge gained today saves the heavy costs of downtime tomorrow. This is the third article in our series of "Managing in the Economic Re-Set."

During the recession at the outset of this decade, high achieving companies like Southwest Airlines, Viacom & Dell not only survived, they thrived. All of them credit training as a being significant factor in their success during a period in which many of their competitors were just struggling to survive. Rather than cutting their training programs and budgets, they increased them.

Flexibility and agility are also key attributes for surviving a recession. Proper training is one of the quickest ways to improve the flexibility and agility of your employees. Relative to the maintenance function, this means that having a well-trained staff that can competently perform multiple skills in a variety of disciplines, is a key to success in your department.

BENEFITS OF TRAINING

Each year, ASTD (American Society for Training and Development, http://www.astd.org/ ) provides a State of the Industry Report, which demonstrates the clear link between learning and performance in successful enterprises. Staff who receive formal training can be much more productive than untrained colleagues who are working in the same role. The benefits of training go far beyond an individual just being able to do a better job. Training can be a recession solution!

Top 10 Employee Benefits –

-Improves Morale because Employees Feel Valued
-Boosts Confidence
-Provides Motivation
-Allows for Career Advancement
-Inspires Personal Satisfaction
-Enables a Willingness to Take on Greater Responsibility
-Improves Communication with More Experienced workers
-Sets the Tone for New Hires
-Prevents Unsafe Work Practices
-Reduces On the Job Injuries

Top 10 Manager Benefits

-Happier Employees (and it spreads!)
-More Self-Reliant Employees
-More Flexible Employees
-Fewer Fires to Put Out
-Improved Use of Your Time
-Lower Stress Levels
-Easier Budget Management
-Makes the Overall Job Easier
-More Likely to Maintain a “Hero” Status
-Improves Career Advancement

Top 10 Company Benefits

-Ensures the Future of the Company
-Less Down Time or Business Interruption
-Improved Life of Equipment
-Increased Accuracy and Efficiency
-Improved Capacity or Cycle Time
-Increased Innovation / New Perspectives
-Increased Sales / Revenues/Profits
-Minimizes Liability & Lowers Insurance Costs
-Enhances Company Image
-Lower Employee Turnover / Attracts New Employees5

5 Benefits for the Customer

-Improved Product Quality
-Improved Customer Service
-Lower Cost
-Greater Confidence
-Better Overall Satisfaction

Second in Our Series: Managing in the Economic Re-Set

NEGATIVE EFFECTS OF DOWNTIME

The true cost of downtime is usually much more than is reported. This is due to the fact that downtime eventually weaves its negative effects throughout everything a company does. Consider the effect downtime has on the wear and tear of other properly operating equipment, the stress it causes to workers and management, the impact it has on employee morale, the product quality issues that may arise, complaints by customers, and the time and money lost because of all these extra circumstances. Downtime at your facility can even directly affect the local and national economy.

DETERMINING THE TRUE COST OF DOWNTIME

There are a variety of methods and calculators for determining downtime costs. In general however, you need to calculate:

-How many employee hours are lost to non-productivity while the system is down, and then convert those lost hours into dollars
-How many hours maintenance and other personnel spend repairing and getting the system back up and running, and convert those lost hours into dollars
-How many hours the facility or unproductive machinery is burning up energy and resources, and convert those lost hours into dollars
-How many hours management and administrative employees spend researching replacement parts, expediting orders or doing other “rush” related work, and convert those lost hours into dollars
-How many hours customer service or sales personnel will spend explaining the downtime to customers and the effect it will have on them, and covert those hours into dollars
-How many sales are lost due to the downtime, and convert those lost sales into dollars
-How many customers are lost due to the downtime, and convert the future value of those customers to dollars.
Add all these figures up and add 10 to 20% to account for the less visible or intangible damages associated with downtime like lower employee morale, stress related non-productivity, negative publicity, etc. and you arrive at a minimum cost of downtime.

AVOIDING DOWNTIME

Clearly, the “best defense” as they say, is a “good offense”. This means being “proactive”, and not “reactive”, in your maintenance responsibilities. Running a plant on a proactive maintenance basis makes your work much more efficient, productive, profitable, and less stressful. This is because being proactive is the best way to reduce and eliminate downtime.

Managing in the Economic Re-Set

We created an excellent paper a few years back about "The Hidden Value of Maintenance". What was true in good times is even more pertinent in tough times. Over the next few weeks, we'll re-visit some of those subjects that contribute to maintenance value in the workplace.

We'll look at the effect of tight budgets, the true cost of downtime, and managing and training around the obstacles. Times may be tough, but the reading is good. Your feedback is welcome!

TOP 8 MISTAKES IN MAINTENANCE WITH TIGHT BUDGETS

1. Change for the Sake of Change – When times are tough, people have a tendency to try and over-control the situation, often making it much worse. As a result, they make changes in hopes of improving a situation, but without really knowing that maybe what they are already doing is already the best thing. The changes they make often come with much more work for everyone that doesn’t produce much, but only gives them a sense of being able to say “we tried everything”. So don’t over react. If you had a maintenance strategy or processes you believed in when times were good, then how much more important is it to stay the course on that strategy when times are bad?
2. Not Focusing on the Fundamentals – Working on new projects means something else won’t get done. Make sure the basics are covered and the fundamentals of keeping your plant up and running are not neglected.
3. Cuts in the Training Budget – You might make some short term gains on a budget issue, but the cost will only show up somewhere else, and in much bigger numbers. “Turning-them-loose-training” (learning from your mistakes), “Follow “Old Joe Training” (learning bad habits from others), and “Band-aid-training” (sitting a worker in front of a boring video or webcast), while sometimes are good supplements, are poor substitutes for professional training from a live human being. The costs for taking these shortcuts will eventually surface.
4. Communication Neglect – People tend to keep their heads low when they are stressed. This causes poorer communication across all lines at a time when it is more important than ever to have clear and consistent communication to pull your company through.
5. Employee Neglect – If management is stressed, you can bet the employees are too. Forgetting to remind people of the good job they have done or acknowledging their accomplishments will only make the situation worse. Improve their morale by letting them know you appreciate their work.
6. Putting Off Small Repairs – The stories are endless about companies who “hold off” on minor repairs during a budget crisis so that they can concentrate the bigger issues, only to have their neglected small repair become the bigger issue.
7. witching Vendors to Save a Buck – If the lowest priced vendor wasn’t good for your company before, what makes you think they will be good for your company now? Trying to save money on a $1,000 component might sound like a good idea until you have to face a shut down for days or weeks at a time because it hasn’t been delivered. Stick with what has kept you up and running.
8. Laying off the Wrong People for the Wrong Reason – Don’t create a worse problem down the road than you already have. Maybe laying off the young novice to keep “Old Joe” around sounds like a good decision, but not if Old Joe decides to retire in the next year and leaves you high and dry. Likewise, laying off Old Joe because he makes the most money might help your short-term budget, but if he really can “do it all”, you probably need to figure out a way to keep him around. Be careful to analyze your needs and company polices before making a quick decision. Knowing your employees on a more personal level can help to clarify these decisions as well.