1. After this training you will be able to:
Define a Preventive Maintenance (PM) system
Recognize reasons and need for a PM system
Define advantages of a PM system
Recognize risks of a PM system
State the law of PM
Describe the PM execution process
Describe ways to fix data absence
Define ways to motivate PM workers.
2. • Preventive maintenance is a schedule of
planned maintenance actions aimed at the
prevention of breakdowns and failures.
• The primary goal of preventive maintenance
is to prevent the failure of equipment before
it actually occurs.
• Designed to:
– Preserve and enhance equipment reliability
by replacing worn components
– Ensure machine failures are not the cause for
workplace mishaps.
3. A written preventive and predictive maintenance
system must be in place
Equipment must be replaced or repaired on a
schedule, following manufacturers’
recommendations
Documented records of maintenance and
repairs must be kept
The system must include maintenance of
hazard controls such as machine guards,
exhaust ventilation, mufflers, control circuits and
devices, etc.
4. • A PM system aligns with a
safety management
program to:
– Prevent injuries caused by
malfunctioning equipment
– Increase automation
– Reduce losses due to
production delays
– Improve quality
– Just-in-time manufacturing
– Provides a more organized
work environment. Image courtesy of www.defenselink.mil
5. Some advantages of a PM system include:
◦ Reduced production downtime
◦ Conservation of assets and increased life
expectancy of assets (both machine and human)
◦ Ensuring all equipment safety features are
functioning properly
◦ Reduced cost of repairs by reducing secondary
failures
◦ Quality products
◦ Identification of equipment with excessive
maintenance costs
6. PM program risks could
include:
◦ Damage to adjacent equipment
during a PM task
◦ Damage due to an error in
reinstalling equipment into its
original location
◦ Damage due to the installation of
new parts.
Image courtesy of www.defenselink.mil
7. The higher the value of plant assets and
equipment per square foot of facility, the
greater will be the return.
8. Things to consider after completing a
maintenance operations:
◦ Ensure equipment meets manufacturer’s
specification
◦ Review job hazard analysis (JHA) to ensure
equipment alterations or equipment maintenance
did not introduce new hazards
◦ Conduct machine checks to ensure all features,
especially safety devices, are functioning properly
◦ Ensure employees are aware of any changes to
equipment and/or operating procedures.
9. Three keys for a successful
PM system:
◦ Scheduling: Should be
automated to the maximum
extent possible
◦ Execution: Should be done
before an actual break down
occurs
◦ Quality: Should have a formal
process for checking the quality
of repairs.
10. • PM focus should be on:
– Cleaning
– Lubrication and inspection
– Correcting deficiencies
– Operation of safety
devices.
• Pre-determined part
replacement should be
minimal and done only
where evidence clearly
indicates wear-out
characteristics.
Image courtesy of www.defenselink.mil
11. When PM data is missing
capture techniques should
look at:
◦ Structural/facility
◦ Age exploration programs
◦ Statistical analysis
◦ Safety inspection data.
Cost should not be a
primary factor in deciding
against data collection for
a PM system.
Image courtesy of www.defenselink.mil
12. • Ways to motivate your PM workers
include:
– Establishing effective training programs
– Establishing inspection and preventive
maintenance as a recognized, important part
of the overall maintenance program,
including follow-ups
– Assigning competent, responsible people to
the preventive maintenance program
– Setting high standards
– Publicizing reduced costs with improved up-
time and revenues and employee safety,
which are the result of an effective
preventive maintenance system.
13. In this presentation you learned about:
Preventive Maintenance Program components
Reasons for the PM system
Advantages of a PM system
PM risks
PM after action items
Successful PM system
PM focus
Ways to motivate PM workers.
Editor's Notes
Preventive maintenance activities include equipment checks, 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. Its purpose is to minimize breakdowns and excessive depreciation. Neither equipment nor facilities should be allowed to go to the breaking point. In its simplest form, preventive maintenance can be compared to the service schedule for an automobile. If the automobile is not maintained properly, it might break down at an unexpected time. Likewise, when the machinery breaks down unexpectedly, it could result in lost production and impact readiness.
Increased automation has caused a greater need for effective PM systems. PM facilitates a successful and continuous flow of activities. A halt in the process would cause losses due to production delays.
Since production delays will have an adverse effect on readiness, a PM system is a central part of a world class safety program.
1.Reduced production downtime will be the result of proper maintenance of the equipment.
2.Conservation of assets -When equipment is properly maintained it would increase and maintain the life expectancy of a certain asset. This concept can be understood through the simple example of a automobile maintenance. When a car is maintained properly it would run smoothly, if not it would start causing problems half way through of its life cycle.
3.Timely routine repairs - One other argument for a PM system is that, routine checks and repairs would be less expensive than large scale repairs which would require intensive repairs causing longer system break-downs.
4.Better Quality Products - Reduced product rejects, rework, and scrap due to better overall equipment condition.
5. Identification of equipment with excessive maintenance costs - This would indicate the need for corrective maintenance (maintenance technique which takes a reactive approach), comprehensive operator training, or replacement of obsolete equipment.
Improved safety and quality conditions.
One potential risk of PM would be the damage that might occur to the adjacent equipment that is around the equipment that is being maintained. These kind of errors might occur due to accidents such as oil leaks, re-connection errors and etc.
Every time new parts are being installed, the equipment goes through the infant stage where it will either fail or succeed. This uncertainty of the new part of working properly is referred to as the infant morality. Since, reintroduction of a new part reintroduces infant morality to that particular equipment, it is considered as a potential risk of PM.
A lot of the errors that occur due to PM, occur as a result of errors in reinstalling equipment into its original location. To emphasize this point, you can ask the trainees of situation where they had taken something apart and wasn’t able to put it back to its original form or maybe had extra hardware left over after reassembly.
There are many advantages for having a good preventive maintenance program. The advantages apply to every kind and size of plant. For instance, downtime in an automobile plant assembly line at one time cost $10,000 per minute. Relating this to lost production time an automobile manufacturer reported that the establishment of a PM program in their 16 assembly plants reduced downtime from 300 hours per year to 25 hours per year. With results such as this no well-managed plant can afford not to develop a PM program.
PM should be implemented when and only the equipment or component under consideration has an increasing failure rate which means the failure rate should increase with time, implying wear out. PM of a component that has a constant rate of failure would not be sensible because such components could be replaced without the implementation of a PM system. We can just replace such components with a new item just by monitoring the duration of use since it has a constant failure rate.
2. In the overall cost for a corrective action, one should include ancillary tangible and/or intangible costs, such as downtime costs, loss of production costs, lawsuits
over the failure of a safety-critical item, loss of goodwill, etc.
Priority should be given to preventive maintenance and a very aggressive program to monitor the schedule and ensure that the work is completed according to schedule should be in place. If PM scheduling isn’t sorted out properly it could delay production or repair processes, Therefore, through automation we can ensure proper maintenance takes place as required.
Execution – Without proper execution, the PM program will not provide the desired results which would result in the same consequences as a failure in scheduling. This will be discussed in detail in the next slides.
In order to ensure a successful PM system, the system should focus mainly on cleaning, lubrication and correcting deficiencies that are found through testing and inspecting the equipment. Without proper testing and inspection, it is not possible to decide whether to implement a PM program or when to implement it. For cost reduction purposes and efficiency of the program, it’s vital to keep the predetermined part replacement to a minimal and done only where statistical evidence clearly points out wear-out characteristics. If the components are not yet in a wear-out stage its best to continue with a PM system to extract the maximum life from it given that the component has an increasing failure rate and the cost of PM is less than corrective control.
Age exploration programs – When prior data is absent to make the decision on PM, a facility should engage in age exploration programs to determine life expectancy, find out critical times in component life cycle, comparisons with similar products to identify problem points of the component.
Statistical Analysis – Is the use of statistical methods to decide when to implement a PM system. This requires the action of an age exploration to collect the data that is needed to come with the analysis.
When prior data is absent, implementing a PM system would be more costly because of the money that needs to be spent on information collection. However, if a company decides not to implement PM just because of the extra cost, it is very likely that they would incur more costs as a result of sudden system breakdowns.
Ask your trainees of some of the motivational elements that could be implemented to ensure that the PM program is being valued by employees.
Then discuss the importance of each of these motivational factors and how they apply to your firm.
Emphasis the importance of a motivated set of employees for a successful PM program.
Provide training in precision maintenance practices and training in the right techniques and procedures for preventive maintenance on specific equipment.
Don’t forget to publicize the improvements in down time and the resulting cost savings over the long term when an effective PM system is in place. Over time statistical analysis should bear this facts out. A goof PM systems saves money.
PM is not difficult to achieve
It is an essential part for cost reduction
There is an element of risk involved in PM
Careful planning and execution will reduce the risk of PM
The biggest benefits of a PM program occur through painting, lubrication, cleaning and adjusting, and minor component replacement to extend the life of equipment and facilities.
