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The Changing Role of Maintenance by Professor John Sharp COrE Research Group, University of Salford, UK www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Where I come from
Salford/ Manchester
Salford is 320km North of London Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
www.ipamc.org
Professor John Sharp • • • • • • •
Apprentice trained (Rolls Royce Aero Engines) Mechanical Engineering first Degree Chartered Mechanical Engineer Doctorate by research Management Experience (Textiles & Unilever) Facilitating and Consultancy On-going research into Organisational Excellence
• 16 years education • 16 years in industry (Sponsored Degree and PhD) • 17 years at Salford www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Organisational Excellence Organisational Excellence (high performance) is achieved by an organisation when it unleashes the potential of all its employees toward their stakeholders’ shared purpose. www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Research Activities – People Process Interface – Process Based Management (quality and operations [maintenance]) – Development of employees & organisations – Corporate Social Responsibility (CSR) leading to
High performance teams & organisations. www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Maintenance Evolution 1940
Perception
1950
Necessary Evil Breakdown
1960
1970
1980
1990
2000
Technical Profit Positive specialisation Contributor Co-operation Preventive Predictive (CBM) TPM RCM Lean Strategic
Maintenance Strategies Post-war boom Global Economy Technology focus External Influences
Oil Crisis Market focus
Recession Customer focus
Global
Maintenance is changing its role as it contributes to its organisation supplying quality products and services, thereby adding value. www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Influences on Changing Roles of Maintenance • Technological Knowledge and Experience (Design) • Maintenance Strategies (PM, CBM, RCM, TPM, Design Out, Lean, etc) • • • •
Partnering (Contracting/Outsourcing) Maintenance Management Data (analysis, IT/IS) Maintenance Processes (added value) www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Agility in Maintenance Management Agility will become very important in industry over the next few years. Agility can be described as:-
“Ability to thrive in a continually and unpredictably changing environment while operating in a competitive climate” (Kidd, 1994)
www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Agility in Maintenance Management • • • • • • •
Knowledge Management Effective Information Systems Effective Enterprise Integration Real-Time Plant Management Waste Management and Elimination Change and Risk Management (Quality Focus [Customers]) www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Six Key Enablers for Maintenance Agility Effective Information Systems Knowledge Management
Change and Risk Management
Effective Enterprise Integration
Taking into account the human aspects
Waste Management and Elimination Real -Time Plant Management
www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
The Changing role of Maintenance requires additional skills (Competencies)
www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
The Traditional Maintenance Engineer • Time served (apprentice trained artisan) • “Hands-on” • Fire-fighting • Vocational Qualification • Command & Control. Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
www.ipamc.org
Maintenance Engineer for the Future From This
To This
Plan A Firefighting C
P Strategy
FOG
D
www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Maintenance Engineer for the Future • Higher Qualification (Degree or Masters) • Information (IT)/Data Analysis (FOG) • Facilitator/Co-ordinator • Communication • Systems knowledge Management • Process thinking. Control
Staff Autonomy
www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Change of Skills/Competence Skills Delegated to Operators
New Skills Required by Maintenance Engineers
• • • • • •
• • • • •
Cleaning Bolting Oiling Monitoring Reporting Basic Maintenance Skills/Competence
• •
Delegation Facilitation/Teams Problem Solving Continuous Improvement Managing Change (taking on board new techniques) Resource Management IT/Data analysis
Role of outsourcing? Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
www.ipamc.org
Continuous Improvement in Maintenance
Strategy & Planning
Continuous Improvement Projects
Maintenance Operations
Performance Measurement
www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Typical Plant Spend versus Performance
+ Annual Maintenance Spend (Dollars, £ etc)
X
Plant Performance (Output etc.)
+ www.ipamc.org
Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Typical Plant Spend versus Performance
+ Annual Maintenance Spend
X
Plant Performance (Output etc.)
+ www.ipamc.org
Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Typical Plant Spend versus Performance
+ Annual Maintenance Spend
X
Plant Performance (Output etc.)
+ www.ipamc.org
Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Changing Roles Maintenance staff will have to face the challenges of gaining new: • • • •
Knowledge Professionalism Competencies Values www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Industrial-Academic Collaboration • • • • •
TCS (now KTP) in UK University of Salford + T Bolton Graduate in company (p/t MSc) Applied modern maintenance 1700 ton extruder = downtime 7.5% to 4.6% • 50% increase in output with a 50% Profit Increase (Maintenance budget increased by 9%)
200 yr old company 500 employees
£ Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
www.ipamc.org
CONCLUSIONS The role of maintenance is changing and that means that the role of maintenance personnel (managers, engineers and tradesmen) will also have to change in order for organisations to provide products and services in a global economy. Competencies of maintenance personnel (people and processes) will have to be enhanced in order to meet the new global challenges. www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Thank you for your attention.
Questions ? Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
www.ipamc.org
“The changing role of maintenance”
Where I come from
Salford/ Manchester
Salford is 320km North of London Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
www.ipamc.org
Professor John Sharp • • • • • • •
Apprentice trained (Rolls Royce Aero Engines) Mechanical Engineering first Degree Chartered Mechanical Engineer Doctorate by research Management Experience (Textiles & Unilever) Facilitating and Consultancy On-going research into Organisational Excellence
• 16 years education • 16 years in industry (Sponsored Degree and PhD) • 17 years at Salford www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Organisational Excellence Organisational Excellence (high performance) is achieved by an organisation when it unleashes the potential of all its employees toward their stakeholders’ shared purpose. www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Research Activities – People Process Interface – Process Based Management (quality and operations [maintenance]) – Development of employees & organisations – Corporate Social Responsibility (CSR) leading to
High performance teams & organisations. www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Maintenance Evolution 1940
Perception
1950
Necessary Evil Breakdown
1960
1970
1980
1990
2000
Technical Profit Positive specialisation Contributor Co-operation Preventive Predictive (CBM) TPM RCM Lean Strategic
Maintenance Strategies Post-war boom Global Economy Technology focus External Influences
Oil Crisis Market focus
Recession Customer focus
Global
Maintenance is changing its role as it contributes to its organisation supplying quality products and services, thereby adding value. www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Influences on Changing Roles of Maintenance • Technological Knowledge and Experience (Design) • Maintenance Strategies (PM, CBM, RCM, TPM, Design Out, Lean, etc) • • • •
Partnering (Contracting/Outsourcing) Maintenance Management Data (analysis, IT/IS) Maintenance Processes (added value) www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Agility in Maintenance Management Agility will become very important in industry over the next few years. Agility can be described as:-
“Ability to thrive in a continually and unpredictably changing environment while operating in a competitive climate” (Kidd, 1994)
www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Agility in Maintenance Management • • • • • • •
Knowledge Management Effective Information Systems Effective Enterprise Integration Real-Time Plant Management Waste Management and Elimination Change and Risk Management (Quality Focus [Customers]) www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Six Key Enablers for Maintenance Agility Effective Information Systems Knowledge Management
Change and Risk Management
Effective Enterprise Integration
Taking into account the human aspects
Waste Management and Elimination Real -Time Plant Management
www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
The Changing role of Maintenance requires additional skills (Competencies)
www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
The Traditional Maintenance Engineer • Time served (apprentice trained artisan) • “Hands-on” • Fire-fighting • Vocational Qualification • Command & Control. Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
www.ipamc.org
Maintenance Engineer for the Future From This
To This
Plan A Firefighting C
P Strategy
FOG
D
www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Maintenance Engineer for the Future • Higher Qualification (Degree or Masters) • Information (IT)/Data Analysis (FOG) • Facilitator/Co-ordinator • Communication • Systems knowledge Management • Process thinking. Control
Staff Autonomy
www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Change of Skills/Competence Skills Delegated to Operators
New Skills Required by Maintenance Engineers
• • • • • •
• • • • •
Cleaning Bolting Oiling Monitoring Reporting Basic Maintenance Skills/Competence
• •
Delegation Facilitation/Teams Problem Solving Continuous Improvement Managing Change (taking on board new techniques) Resource Management IT/Data analysis
Role of outsourcing? Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
www.ipamc.org
Continuous Improvement in Maintenance
Strategy & Planning
Continuous Improvement Projects
Maintenance Operations
Performance Measurement
www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Typical Plant Spend versus Performance
+ Annual Maintenance Spend (Dollars, £ etc)
X
Plant Performance (Output etc.)
+ www.ipamc.org
Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Typical Plant Spend versus Performance
+ Annual Maintenance Spend
X
Plant Performance (Output etc.)
+ www.ipamc.org
Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Typical Plant Spend versus Performance
+ Annual Maintenance Spend
X
Plant Performance (Output etc.)
+ www.ipamc.org
Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Changing Roles Maintenance staff will have to face the challenges of gaining new: • • • •
Knowledge Professionalism Competencies Values www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Industrial-Academic Collaboration • • • • •
TCS (now KTP) in UK University of Salford + T Bolton Graduate in company (p/t MSc) Applied modern maintenance 1700 ton extruder = downtime 7.5% to 4.6% • 50% increase in output with a 50% Profit Increase (Maintenance budget increased by 9%)
200 yr old company 500 employees
£ Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
www.ipamc.org
CONCLUSIONS The role of maintenance is changing and that means that the role of maintenance personnel (managers, engineers and tradesmen) will also have to change in order for organisations to provide products and services in a global economy. Competencies of maintenance personnel (people and processes) will have to be enhanced in order to meet the new global challenges. www.ipamc.org Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
Thank you for your attention.
Questions ? Professor John Sharp, University of Salford, UK
“The changing role of maintenance”
www.ipamc.org
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