IMPLEMENTING EFFECTIVE PREVENTIVE MAINTENANCE THE JOURNEY TO ZERO FAILURES

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INTRODUCTION TO IMPLEMENTING EFFECTIVE PREVENTIVE MAINTENANCE – THE JOURNEY TO ZERO FAILURES

Preventive maintenance (PM) has been a familiar principal within industry and manufacturing for several decades. A well designed and well implemented effective preventive maintenance program will extend the life of equipment by reducing replacement costs, preventing most breakdowns that effect efficiency of equipment, improving the effectiveness of the maintenance department, and improving the overall condition of the Assets.

Developing a successful and effective preventive maintenance system from goal setting and equipment inventory through determining the exact procedures to follow for each piece of equipment.

Think about preventive maintenance is by imagining a car. You can let your car run until it breaks down and then take it to get fixed. This is reactive maintenance. Or, you can bring the car into the shop every three months, after 10,000 miles, or at another regular interval recommended by the car’s manual to get the oil changed, the battery looked at, and the tires swapped out. This is preventive maintenance.

 

COURSE CONTENT
Module 1
What is Preventive Maintenance?

  • What is a preventive maintenance program?
  • What does preventive maintenance look like?
    • PM extends equipment life
    • PM reduces costs
    • PM saves energy
    • PM improves the experience of your maintenance personnel’s.
    • PM makes your job easier
  • Other types of preventive maintenance
    • Corrective maintenance
    • Deferred maintenance
    • Run to failure
    • Emergency maintenance
  • What strategy is applicable and effective?

 

Module 2
Build a strategy for managing your Failure Data
Classroom Training/Shopfloor Training

  • What are maintenance metrics?
  • Why are maintenance metrics important?
  • Understand Sporadic Losses
  • Understand Chronic Losses
    • 6 Major Equipment’s Losses
    • Equipment Failure.
    • Setup and Adjustments.
    • Idling and Minor Stops.
    • Reduced Speed.
    • Process Defects.
    • Reduced Yield.

 

Module 3
Measuring the Effectiveness of Maintenance Activities
Classroom Training/Shopfloor Training

  • Measuring maintenance performance
  • Overall Equipment Effectiveness
    • Availability
    • Performance
    • Quality
  • Equipment Reliability analysis
    • MTBF
    • MTTR

 

Module 4
Failure Mode Analysis (FMA) Equipment Selection
Classroom Training/Shopfloor Training

  • Review Equipment design and operation
  • Using 80/20 principle for Equipment Selection
  • Chosen Component – Review failure modes history
  • List root causes of failure modes; the cause of occurrences
  • Assign optimized maintenance task, frequencies and standards

 

 

Module 5
Preventive Maintenance Roadmap Reliability
Classroom Training/Shopfloor Training

  • Step-1 Analysis of the difference between the basic and use condition
    • Understand the issues
    • (Pareto Analysis, 5W-1H, 5 why Analysis,)
  • Step-2 Improvement of the difference between the basic and use condition
    • Maintain basic equipment condition
    • (Clean, replace panels, mounting hardware)
    • TLC-Tighten, Lubricate, Alignment
  • Step-3 Preparation of standards for basic and use condition
    • Maintenance schedules, Inspection Checklist
    • Trouble shooting guides
  • Step-4 Extension of service life
    • Execute corrective maintenance
    • (Improve, Redesign, Use higher technologies)
  • Step-5 Improvement of inspection and maintenance efficiency
    • Detection of internal deterioration,
    • Activities to reduce breakdown maintenance Preventive Maintenance Roadmap Reliability
  • Step-6 Overall equipment diagnosis
    • Revise maintenance standards and enhance
    • Developing Maintenance Skills
    • New technologies Getting your Hands Dirty
    • The first few months of actually doing PM

 

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IMPLEMENTING EFFECTIVE PREVENTIVE MAINTENANCE THE JOURNEY TO ZERO FAILURES

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