Preventive maintenance planning and practices influence most major maintenance department activities in a manufacturing environment. Here are some examples of this.
- Equipment downtime is largely affected by preventive maintenance or the lack there of.
- Repair work orders are subjected to the influences of the preventive maintenance program.
- Purchasing and inventory are affected by preventive maintenance for routine replacement of expendable spares as well as repair parts required for unexpected downtime.
As evidenced by the points above, preventive maintenance should be “first base” for any maintenance department. Unfortunately sometimes routine preventive maintenance activities often do not get the attention or credit they are due. This is a mistake. So what are the keys to a successful preventive maintenance program?
1. Careful Planning of the Preventive Maintenance Program
Planning a preventive maintenance program involves the following:
- Determine tasks and intervals needed to maintain the equipment.
- Ensure that the appropriate resources are in place.
- Schedule maintenance personnel for maximum preventive maintenance wrench time.
- Understand how scheduled equipment downtime and maintenance personnel scheduling interface.
- Manage spares effectively.
- Select a scheduling and accountability system (preventive maintenance software, CMMS software or equivalent)
Determine Maintenance Tasks and Intervals
A good preventive maintenance (PM) task list contains the following components:
- The equipment item.
- The task(s).
- The person the task is assigned to.
- A task interval.
- A start date and due date.
- Optional: Detailed instructions and pictures if needed.
- Optional: Task completion sequence.
Begin with your equipment list. Next gather appropriate tasks for preventive maintenance task lists from OEM manuals or online manuals when possible. This is a good place to start, especially with newer equipment. In some cases, the equipment warranty is dependent upon following the OEM recommendations. Another source of tasks is the maintenance manager’s experience and intuition. Yet another source is branch locations running similar equipment.
When developing a task list, consider the reusability of the task descriptions. Reusability refers to using the same task description on potentially multiple equipment items. The benefit is that there are fewer tasks, no duplicate task descriptions and better reporting and analysis of PMs. Consider these examples: Smart Maintenance
REUSABLE task description: Lubricate Roller Chain(s)
NOT REUSABLE: Lubricate Roller Chain(s) on Conveyor #1
In the first example this task, Lubricate Roller Chain(s), is appropriate for any equipment with a roller chain. In the second example, Lubricate Roller Chain on Conveyor #1, is only appropriate on the Conveyor #1 PM task list. Imagine how cumbersome your preventive maintenance software management efforts become if you are not using reusable tasks. Another example that may cause problems later is naming conventions such as 30 Day PMs or Weekly Tasks. This creates unneeded redundancy, as the interval (30 in this case) is included in the PM record already. Additionally there is no task description here that refers to the actual work performed.
How do you create reusable tasks? Begin with the most generic tasks you can think of and create these first. Examples could be Inspect, Clean, Lubricate, etc. After these task descriptions have been created, go to the next step and create tasks that are somewhat more specific. Here are some examples: Check Wiring, Replace Lubricant, Lube Chains. Continue with increasingly more specific tasks always trying to avoid including the equipment or equipment component in the task description. Eventually, for specialized tasks that are only performed on specific equipment, it may become necessary to include a component of the equipment in the task description. Keep the task description short and focused on the actual task. Obviously if the task description is short, it may not fully describe the job. This is where detailed instructions and pictures are used.