Preventive Maintenance Progam

1. PREVENTIVE MAINTENANCEin Residential LifeMU ResLife Getting Started Mindy Imhoff, Dean Umstattd & Don Welker Administrative, Crew Leader & Crew Member

2. Overview What we have planned Our Preparations Equipment Preparations Gathering Information System that we are using Who is doing what Benefits of Preventive Maintenance Challenges to Implementing

3. Our Planning Learning the Objectives Getting acquainted with the different types of maintenance activities that go along with Preventive Maintenance Learning the values of designing a Preventive Maintenance schedule Keeping aware of the challenges in implementing the Preventive Maintenance

4. Our Planning What are we starting with the data collection Allocating our maintenance resources Keeping track of spare parts are we ordering Revenue, cost, output, uptime, inventory are being recorded to set up a baseline Which equipment to take down for replacement schedules

5. Our Preparations Our goal is to retrieve the data and label equipment Taking the information, identification information and symbol information gathering it to submit into a book Properly tagging the equipment hierarchy (standard equipment tagging) Tracing the equipment’s electrical lines back to the panel to incorporate into the tag ID

6. Our Labeling System

7. Labeled Incorrect

8. Equipment Preparation Going over all equipment on all moving parts For proper alignment of sheaves Pulleys Belts Check bearings Going over equipment nonmoving parts Filters, filter sizes Grease fittings Lubrication oil

9. Gathering Information Make changes while checking equipment Take information and submitting into a book Checking Operating & Maintenance manuals Proper manufacturer recommendations If no information is available, search internet or call manufacturer for best solution Taking camera shots of equipment Tagging all the equipment

10. Shop Reference Book

23. Problem Furnace Fan Coil Unit (FCU) filter change Takes a PM person unreasonable amount of time to replace filters (over 30 minutes) Door difficult to remove and replace due to the ¼ turn screws, no door supports to rest it on and nothing to hang on to the door

26. Solution There is no reason for the Preventive Maintenance crew members to be inside these unitsother than filter changes and pan tabs Putting the filter on the outside, eliminates opening the unit Fabricated a filter bracket and installing a handle on the unit’s door As an end result, it takes seconds Retrofitting these cut down on different sized filters Drilling access hole for pan tab and installing rubber stoppers

28. Calculation Previously: 120 furnaces X 30 minutes a man hour = 60 man hours (not including stocking and disposing of old filters) Solution: 5 minutes per filter 120 furnaces X 5 minutes a man hours = 10 man hours (including stocking and dispose of old filters) SAVING 50 man hours

29. System We are Using TMA We use TMA for our work orders We use TMA for Projects We use TMA for Inventory And Now we are starting our PMs in TMA Our first practice run will be done with the smaller equipment

30. Who is Doing What? PM Crew Leader Setting up, Training, Rebuilding old Equipment, collecting information PM Crew Help setting up, collecting information, repairing and performing regular PMs Administrative TMA data entry

31. PM Schedules Questions Priorities? (time intervals) Fixed for each frequency date? Floating until the previous Preventive Maintenance is complete? Not skipping any 6th month or yearly PMs Seasonal?

32. Benefits of Preventive Maintenance The cost of breakdown maintenance is much greater than preventive maintenance Preventive Maintenance Keeps equipment in good condition to prevent large problems Extends the useful life of the equipment Finds small problems before they become big ones Is an excellent training tool for technicians Keeps equipment safer Parts stocking levels can be optimized Greatly reduces unplanned downtime Reduces injury

33. Challenges to ImplementingPreventive Maintenance Social Factors The benefit of preventive maintenance are not always well understood The focus on minimizing maintenance costs has to shift to maximizing overall organizational performance Technical Factors Crisis/emergency maintenance is typically cheaper than preventive maintenance in the short-term Under-trained technicians can cause more damage than they prevent

34. Concluding Comments Performing preventive maintenance is always the best long-term strategy to maintain equipment Preventive Maintenance scheduling and strategy are keys to maximizing output while reducing work-in-process inventory

35. Questions??Comments Contact information imhoffm@missouri.edu