Post by Ed Bingle on May 13, 2014 8:22:15 GMT -5
PREVENTIVE MAINTENANCE PROGRAM INDUSTRIAL MAINTENANCE TRAINING PROGRAM.
What is Preventive Maintenance? The care and servicing by personnel for the purpose of maintaining equipment and facilities in satisfactory operating condition by providing for systematic inspection, detection, and correction of incipient failures either before they occur or before they develop into major defects. Maintenance; including tests, measurements, adjustments, and parts replacement, performed specifically to prevent faults from occurring.
This definition sums up the basic program directive. Preventive maintenance has many portions that have to be in place for it to be successful.
1. A qualified industrial technician trained in preventive maintenance.
2. There should be at least two trained persons in the maintenance department assigned to the preventive maintenance program.
a. One trained industrial maintenance mechanic.
b. One trained industrial maintenance electrician.
c. When required an industrial maintenance specialist.
3. A daily, weekly, and monthly detailed operation and instructions for each machine, process, tools, and equipment.
4. There should be in place a daily, weekly, and monthly detailed operation and instructions for each machine, process, tools, and equipment for all Machine Operators.
5. A schedule that is not changed and a rule to apply not to change unless by qualified personnel.
6. All tools needed to perform the preventive maintenance program to completion of each cycle.
7. A data system that simplifies how much paper or data entry has to be performed.
8. A schedule that is a true time line to complete each cycle.
9. A tool box custom designed for only this program.
10. Supervision to oversee and tracking quality, safety, directives, and time during.
11. All O. E. M. recommendations for preventive maintenance added to program at time of program start up, or time machine is placed in production.
12. All safety for machines and humans is applied during the program, with proper PPE safety equipment.
13. Lockout / Tagout training and applied during program.
14. All production machine operators and supervisors working with maintenance technician to make scheduling and to assist with this program.
With what has been stated above you can see there is a team working to make this program work.
The preventive maintenance program sounds over whelming, and can be if not put in place correctly.
Don’t treat it as a hit and miss situation. There is no program going to work good or even ok, if you do
not follow the list above. Once you have the program in place one cycle, then you can make needed
adjustment with time and scheduling.
A cycle is one complete schedule where all machine, equipment, and tools have had required
preventive maintenance performed. This by most accounts should work out to be three months.
Example; A manufacturing plant with 8 large process lines and 20 small process lines, support
equipment, transportation equipment, shipping and warehouse machinery, and building should easily
be maintained in a three month cycle.
A preventive maintenance program is not a true program if the machine operators and production
management don’t have the program implemented also. They have to work closely with who is
performing the maintenance and have good communication with working around production
schedules, machine issues, and safety.
There are many ways for this preventive maintenance program to fail.
1. Using personnel from this program for other task not related.
2. Changing schedule too much and cycle is behind or disrupted to an extreme.
3. Not having enough personnel to perform the program.
4. Not following the design of the program.
5. Unsatisfactory supervision of program.
6. Having good support for the program.
Preventive maintenance is a not seen cost savings. This sometimes presents a hard sell when trying to
implement a program. There are ways to present the cost savings that will make good since to any
financial manager. Unless you have a new start up company, there will be a maintenance budget from
the year before. Take a look at your machine work orders and your budget. If there was not
preventive maintenance being done it will be easy to show how you can prevent the machine,
bearing, belts, drives, controls, leaks, and safety failures. Where the biggest cost savings is going to
show up, is production downtime. A good preventive maintenance program should save enough
money to pay for the program with surplus. The company should have better production numbers, on
time delivery, and product quality will improve. A preventive maintenance program properly
performed has no down side. Everything gets better and you can see it. Your maintenance
department has more time to work on upgrades and new machinery instead of repairs. Production
can run better product. And machine operators have more confident in their operation.
Preventive maintenance can be described as maintenance of equipment or systems before fault occurs. It can be divided into two subgroups: Planned maintenance and condition-based maintenance.
The main difference of subgroups is determination of maintenance time, or determination of moment when maintenance should be performed.
While preventive maintenance is generally considered to be worthwhile, there are risks such as equipment failure or human error involved when performing preventive maintenance, just as in any maintenance operation. Preventive maintenance as scheduled overhaul or scheduled replacement provides two of the three proactive failure management policies available to the maintenance engineer. Common methods of determining what Preventive (or other) failure management policies should be applied are; OEM recommendations, requirements of codes and legislation within a jurisdiction, what an "expert" thinks ought to be done, or the maintenance that's already done to similar equipment, and most important measured values and performance indications.
To make it simple: Preventive maintenance is conducted to keep equipment working and/or extend the life of the equipment. Corrective maintenance, sometimes called "repair," is conducted to get equipment working again.
The primary goal of maintenance is to avoid or mitigate the consequences of failure of equipment. This may be by preventing the failure before it actually occurs which Planned Maintenance and Condition Based Maintenance help to achieve. It is designed to preserve and restore equipment reliability by replacing worn components before they actually fail. Preventive maintenance activities include partial or complete overhauls at specified periods, oil changes, lubrication and so on. In addition, workers can record equipment deterioration so they know to replace or repair worn parts before they cause system failure. The ideal preventive maintenance program would prevent all equipment failure before it occurs.
What is Preventive Maintenance? The care and servicing by personnel for the purpose of maintaining equipment and facilities in satisfactory operating condition by providing for systematic inspection, detection, and correction of incipient failures either before they occur or before they develop into major defects. Maintenance; including tests, measurements, adjustments, and parts replacement, performed specifically to prevent faults from occurring.
This definition sums up the basic program directive. Preventive maintenance has many portions that have to be in place for it to be successful.
1. A qualified industrial technician trained in preventive maintenance.
2. There should be at least two trained persons in the maintenance department assigned to the preventive maintenance program.
a. One trained industrial maintenance mechanic.
b. One trained industrial maintenance electrician.
c. When required an industrial maintenance specialist.
3. A daily, weekly, and monthly detailed operation and instructions for each machine, process, tools, and equipment.
4. There should be in place a daily, weekly, and monthly detailed operation and instructions for each machine, process, tools, and equipment for all Machine Operators.
5. A schedule that is not changed and a rule to apply not to change unless by qualified personnel.
6. All tools needed to perform the preventive maintenance program to completion of each cycle.
7. A data system that simplifies how much paper or data entry has to be performed.
8. A schedule that is a true time line to complete each cycle.
9. A tool box custom designed for only this program.
10. Supervision to oversee and tracking quality, safety, directives, and time during.
11. All O. E. M. recommendations for preventive maintenance added to program at time of program start up, or time machine is placed in production.
12. All safety for machines and humans is applied during the program, with proper PPE safety equipment.
13. Lockout / Tagout training and applied during program.
14. All production machine operators and supervisors working with maintenance technician to make scheduling and to assist with this program.
With what has been stated above you can see there is a team working to make this program work.
The preventive maintenance program sounds over whelming, and can be if not put in place correctly.
Don’t treat it as a hit and miss situation. There is no program going to work good or even ok, if you do
not follow the list above. Once you have the program in place one cycle, then you can make needed
adjustment with time and scheduling.
A cycle is one complete schedule where all machine, equipment, and tools have had required
preventive maintenance performed. This by most accounts should work out to be three months.
Example; A manufacturing plant with 8 large process lines and 20 small process lines, support
equipment, transportation equipment, shipping and warehouse machinery, and building should easily
be maintained in a three month cycle.
A preventive maintenance program is not a true program if the machine operators and production
management don’t have the program implemented also. They have to work closely with who is
performing the maintenance and have good communication with working around production
schedules, machine issues, and safety.
There are many ways for this preventive maintenance program to fail.
1. Using personnel from this program for other task not related.
2. Changing schedule too much and cycle is behind or disrupted to an extreme.
3. Not having enough personnel to perform the program.
4. Not following the design of the program.
5. Unsatisfactory supervision of program.
6. Having good support for the program.
Preventive maintenance is a not seen cost savings. This sometimes presents a hard sell when trying to
implement a program. There are ways to present the cost savings that will make good since to any
financial manager. Unless you have a new start up company, there will be a maintenance budget from
the year before. Take a look at your machine work orders and your budget. If there was not
preventive maintenance being done it will be easy to show how you can prevent the machine,
bearing, belts, drives, controls, leaks, and safety failures. Where the biggest cost savings is going to
show up, is production downtime. A good preventive maintenance program should save enough
money to pay for the program with surplus. The company should have better production numbers, on
time delivery, and product quality will improve. A preventive maintenance program properly
performed has no down side. Everything gets better and you can see it. Your maintenance
department has more time to work on upgrades and new machinery instead of repairs. Production
can run better product. And machine operators have more confident in their operation.
Preventive maintenance can be described as maintenance of equipment or systems before fault occurs. It can be divided into two subgroups: Planned maintenance and condition-based maintenance.
The main difference of subgroups is determination of maintenance time, or determination of moment when maintenance should be performed.
While preventive maintenance is generally considered to be worthwhile, there are risks such as equipment failure or human error involved when performing preventive maintenance, just as in any maintenance operation. Preventive maintenance as scheduled overhaul or scheduled replacement provides two of the three proactive failure management policies available to the maintenance engineer. Common methods of determining what Preventive (or other) failure management policies should be applied are; OEM recommendations, requirements of codes and legislation within a jurisdiction, what an "expert" thinks ought to be done, or the maintenance that's already done to similar equipment, and most important measured values and performance indications.
To make it simple: Preventive maintenance is conducted to keep equipment working and/or extend the life of the equipment. Corrective maintenance, sometimes called "repair," is conducted to get equipment working again.
The primary goal of maintenance is to avoid or mitigate the consequences of failure of equipment. This may be by preventing the failure before it actually occurs which Planned Maintenance and Condition Based Maintenance help to achieve. It is designed to preserve and restore equipment reliability by replacing worn components before they actually fail. Preventive maintenance activities include partial or complete overhauls at specified periods, oil changes, lubrication and so on. In addition, workers can record equipment deterioration so they know to replace or repair worn parts before they cause system failure. The ideal preventive maintenance program would prevent all equipment failure before it occurs.