WRITING A SMART INSPECTION PLAN

Like most business plans and strategies, an inspection plan should be built top-down.

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It should begin with a clear statement of corporate goals and objectives related to asset management. This approach is addressed in ISO 55001 on asset management. ICML 55, the global standard by the International Council for Machinery Lubrication, addresses optimized management of lubricated assets and is aligned with ISO 55001 guidelines. It covers inspection plans. The following refers to developing plans for Inspection 2.0, bringing inspection to a level as high or higher than condition monitoring technologies often used concurrently.

A full-on Inspection 2.0 plan should be a detailed and comprehensive document to ensure that key features and functional elements are not overlooked. From there, it can be abridged or streamlined for quick, readable review by technicians and operators. The unabridged version of the plan can also serve as a rough curriculum for training and competency testing for current and aspiring new inspectors.

Modern reliability and asset management programs expect documented, procedure-based work plans. This reduces the risk of variability, uncertainty and drift over time. The plan is best if it is consensus-based and should be continually improved. Before considering the input of stakeholders in writing the inspection plan, it is best to get everyone on the same page through training or self-study on the fundamental elements of Inspection 2.0 and condition-based maintenance. Of course, RCM, TPM, and asset management training would also be helpful.

Consensus-based inspection plans tap into the knowledge base and experience of skilled practitioners, old-timers and others with valuable craft skills. This provides a helpful foundation for the machine’s operating conditions, critical inspection points, reliability history and known failure modes. It also establishes buy-in or ownership among operators, mechanics, technicians and other stakeholders who will be asked to execute and respond to the plan.