How To Build Preventive Maintenance Program

OLEH

ISMAIL YUSOF

How to Build Preventive Maintenance Program

PM SHOULD DETERMINE A MAJOR PORTION OF THE WORK PERFORMED

- ON A DAY-TO-DAY OR WEEK-TO-WEEK BASIS.

- THE WORK IS PRE-PLANNED. - LABOR ESTIMATES, MATERIAL, AND - TOOL REQUIREMENTS ARE KNOWN.

Determine Preventive Maintenance

- PM IS THE MOST IMPORTANT WORK PERFORMED DURING A NORMAL WORKDAY SOMETIMES RECEIVES CHUCKLES FROM PEOPLE WHO WORK IN MAINTENANCE.

- PM WORK IS THE FIRST TO BE DISPLACED FROM THE SCHEDULE BY EMERGENCY WORK OR OTHER SO CALLED "MORE IMPORTANT WORK".

- THE LOW REGARD PM HAS IN SOME PLANTS MAY BE DERIVED FROM A LACK OF QUALITY AND FOCUS ON THE EFFORT. LOTS OF TIME GOES INTO THE INITIAL SALE OF A PM EFFORT, BUT LITTLE TIME INTO THE ACTUAL WORK PERFORMED

Determine Preventive Maintenance

- SMALL STEPS TOWARD A COMPLETE PROGRAM CAN BE EVEN MORE EFFECTIVE THAN FIRST ESTABLISHING A "MASTER PLAN".

- HOWEVER, PRIORITIZING YOUR EFFORT SHOULD BE AN INITIAL STEP.

Initial Step

IDENTIFY THE EQUIPMENT WITH - HIGH DOWNTIME, - HIGH MAINTENANCE, OR - REPETITIVE REPAIRS.

THIS IS USUALLY A SMALL PERCENTAGE OF THE TOTAL EQUIPMENT IN THE PLANT. ABC ANALYSIS (80-20 RULE) OR OLD FASHIONED "FAT FILES" MAY HELP IN THIS IDENTIFICATION.

Identify

- TAKE ONLY THE TOP ONE OR TWO PIECES OF EQUIPMENT ON THE LIST AND ATTEMPT TO IDENTIFY THE ROOT CAUSE OF THE PROBLEMS MOST COMMONLY ENCOUNTERED.

- A DETAILED REVIEW OF WORK ORDER HISTORY MAY YIELD THE SOURCE.

- A BRAINSTORMING SESSION WITH OPERATIONS AND MAINTENANCE PERSONNEL CAN BE JUST AS PRODUCTIVE.

- PM PROGRAMS WHICH ARE DEVELOPED WITH THE INVOLVEMENT OF OPERATIONS HAVE PROVEN TO BE THE MOST SUCCESSFUL.

Review

D E V E LO P A S O L I D P M P R O C E D U R E T O C O M B AT T H E R O O T C AU S E O F T H E P R O B L E M . - A P M W O R K O R D E R I S H A N D E D T O A M A I N T E N A N C E W O R K E R

W I T H O U T A N Y M O R E D E TA I L T H A N A S TAT E M E N T S U C H A S , " P M T H E P L A N T A I R C O M P R E SS O R " , O R " I N S P E C T T H E G E A R B OX " .

- T H E M E C H A N I C I S E X P E C T E D T O D R AW O N P E R S O N A L K N O W L E D G E O F E Q U I P M E N T A N D D O A L L T H E P R E V E N T I V E W O R K R E Q U I R E D . W H AT I S A C T UA L LY A C C O M P L I S H E D C A N VA RY W I D E LY F R O M O N E E M P LOY E E T O T H E N E X T, A N D T H E W O R K P E R F O R M E D M AY N O T E V E N B E T H E W O R K I N T E N D E D BY T H E M A N A G E R .

- T H E T I M E TA K E N O U T O F T H E N O R M A L W O R K D AY T O P E R F O R M P M S H O U L D B E P R O D U C T I V E . T O I M P R OV E T H E P R O D U C T I V I T Y, T H E W O R K N E E D S T O B E W E L L D E F I N E D . A W R I T T E N P R O C E D U R E W I T H A D ATA S H E E T S H O U L D B E D E V E LO P E D F O R M O S T P M W O R K .

Develop Preventive Procedure

INSPECTIONS : - AN INSPECTION IS USUALLY PERFORMED ON OPERATING

MACHINERY USING THE BASIC SENSES OF S IGHT, SOUND, AND TOUCH.

- THE QUALITY OF THE INSPECTION IS TOTALLY DEPENDENT ON THE SENSIT IV ITY OF THE INSPECTOR TO POTENTIAL EQUIPMENT PROBLEMS.

- ASSOCIATED CHECKLISTS USED ON INSPECTIONS ARE OFTEN JUST A L IST OF EQUIPMENT, THE SYMPTOMATIC CONDIT IONS TO BE LOOKED FOR , AND A LOCATION ON THE CHECKLIST WHERE A "CHECK MARK" IS TO BE ENTERED. SUCH CHECKLISTS OFTEN BECOME ABUSED, WITH INSPECTORS HURRIEDLY F ILL ING IN THE CHECK MARKS OR EVEN COMPLETING THE FORMS BACK IN THE SHOP.

The following types of PM procedures should be

considered:

I N S P E C T I O N S :- C A N B E E N H A N C E D BY A D D I N G G AU G E S O R I N S T R U M E N T

I N S P E C T I O N S T O T H E R O U T E . R O TAT I N G C O M P O N E N T S O R D R I V E B E LT S C A N B E I N S P E C T E D U N D E R T H E " F R E E Z I N G " A C T I O N O F A B AT T E RY P O W E R E D S T R O B E L I G H T.

- B E LT D R I V E I N S P E C T I O N C A N B E E X PA N D E D T O I N C LU D E T H E U S E O F S H E AV E G AU G E S A N D B E LT T E N S I O N G AU G E S .

- C R I T I C A L T E M P E R AT U R E L I M I T S O N B E A R I N G S O R C O M P R E SS O R VA LV E S C A N B E D E T E R M I N E D BY U S I N G A N I N E X P E N S I V E T E M P E R AT U R E I N F R A R E D P Y R O M E T E R .

- V I B R AT I O N C H E C K S U S I N G LO W C O S T, P E N S I Z E D M E T E R S C A N B E U S E D T O D E T E C T B E G I N N I N G P R O B L E M S I N E Q U I P M E N T D U E T O I M B A L A N C E , M I S A L I G N M E N T, O R

- LO O S E N E SS . A D D I N G S U C H I N N OVAT I O N S T O A N I N S P E C T I O N O F T E N R A I S E S T H E I N T E R E S T L E V E L O F T H E I N S P E C T O R A S W E L L A S H E I G H T E N S T H E Q UA L I T Y O F I N F O R M AT I O N R E T U R N E D .

The following types of PM procedures should be considered:

ADJUSTMENTS INVOLVE THE OPTIMIZATION OF OPERATING EQUIPMENT. - IT COULD BE A SIMPLE FINE TUNING OF CAM

ON A LIMIT SWITCH, OR COULD INVOLVE THE TUNING OF A BOILER COMBUSTION CONTROL SYSTEM TO MAXIMIZE FUEL EFFICIENCY.

- A RECORD OF ADJUSTMENTS MADE CAN BECOME THE BASIS FOR OPTIMIZING THE PM FREQUENCY, OR CAN POINT TO THE NEED FOR COMPONENT REPLACEMENT IF TOO FREQUENT ADJUSTMENTS MUST BE MADE.

Adjustment

- TESTS ARE USED TO VERIFY THAT EQUIPMENT IS PERFORMING ACCORDING TO SPECIFICATIONS AND ARE OFTEN ASSOCIATED WITH SAFETY CONTROLS OR ENVIRONMENTAL EQUIPMENT.

- A TYPICAL PM OF THIS TYPE MIGHT BE USED TO VERIFY THE AUTOMATIC SHUTDOWN CONTROLS ON A BOILER STEAM DRUM.

- DOCUMENTATION IS OFTEN REQUIRED WHEN PERFORMING THESE TYPES OF TESTS. THEY SHOULD INCLUDE A FORM WHICH SHOWS THE DATE AND RESULTS OF THE TEST, AND SHOULD BE SIGNED BY THE TESTER.

Testing

- CALIBRATION VERIFIES OR CORRECTS THE ACCURACY OF CRITICAL INDICATORS, CONTROL INSTRUMENTATION, OR FINAL ELEMENTS.

- A DATA SHEET SHOULD BE INCLUDED WHICH INDICATES "AS FOUND", "CORRECT", AND "AS LEFT" CONDITION.

- THESE SHEETS SHOULD BE SIGNED AND DATED .

Calibration

- REBUILD INVARIABLY REQUIRES EQUIPMENT DOWNTIME. DURING A REBUILD, CRIT ICAL DIMENSIONS ARE CHECKED AND WORN PARTS REPLACED.

- THE GOAL OF A REBUILD IS TO RESTORE EQUIPMENT TO "L IKE NEW" CONDIT ION. REBUILDS ARE SOMETIMES TURNED OVER TO AN OUTSIDE VENDOR.

- THE VENDOR MAY BE THE ORIGINAL EQUIPMENT MANUFACTURER (OEM) OR A SERVICE VENDOR FAMIL IAR WITH THE MACHINERY'S MAINTENANCE REQUIREMENTS. IN E ITHER CASE,

- THE CONCLUSION OF THE REBUILD SHOULD INCLUDE A DETAILED REPORT COVERING WHAT WAS DONE, WHAT WAS FOUND, WHAT WAS REPLACED, AND WHAT SHOULD BE CHECKED ON THE NEXT REBUILD.

Rebuild

- REPLACEMENT PMS CAN INVOLVE THE PERIODIC REPLACEMENT OF DISPOSABLE COMPONENTS, SUCH AS AIR , OIL, OR FUEL FILTERS.

- REPLACEMENT PMS CAN ALSO INCLUDE REPLACE-IN-KIND FOR INEXPENSIVE BUT CRITICAL EQUIPMENT. OFTEN, SUCH REPLACEMENTS ARE ECONOMICALLY JUSTIFIED OVER MORE FREQUENT INSPECTIONS.

- A TYPICAL REPLACEMENT PM WOULD BE REPLACEMENT OF INEXPENSIVE POSITIVE DISPLACEMENT FUEL OIL PUMPS AT THE BEGINNING OF THE WINTER SEASON.

Replacement

1. A L IST OF TOOLS, PARTS, OR INSTRUMENTS REQUIRED TO PERFORM THE PM SHOULD BE PROVIDED AT THE BEGINNING OF EVERY PROCEDURE

2. A FORM MUST BE PROVIDED IF THE PM PROCEDURE INCLUDES TAKING MEASUREMENTS OR READINGS, SO THIS INFORMATION CAN BE RECORDED.

3. IF MEASUREMENTS OR READINGS ARE TAKEN, THE DATA FORM MUST INCLUDE A L IMIT OR RANGE OF VALUES, WHICH WILL INDICATE WHETHER OR NOT THE MEASUREMENT OR READING IS NORMAL

4. SAFETY CONSIDERATIONS SHOULD BE L ISTED, SUCH AS "LOCK-OUT" OR "HOT-WORK" PROCEDURES.

Good PM procedures should incorporate the following elements:

1 . V E N D O R R E C O M M E N D E D P M : - T H E M A I N T E N A N C E M A N UA L S P R O V I D E D B Y E Q U I P M E N T

M A N U FA C T U R E R S A R E I N VA LUA B L E W H E N T RY I N G T O B U I L D A P M P R O C E D U R E .

- H O W E V E R , T H E P R O C E D U R E I N T H E M A N UA L S H O U L D N O T B E U S E D I N I T S O R I G I N A L F O R M .

- A D D I T I O N A L T E S T S, R E PA I R S O R I N S P E C T I O N S S H O U L D B E A D D E D W H I C H R E F L E C T T H E S P E C I A L U S E O F T H E M A C H I N E I N Y O U R FA C I L I T Y. A S A N E XA M P L E , I F A C O M P R E SS O R N O R M A L LY O P E R AT E S AT A N O V E R L O A D,

- R O U T I N E I N S P E C T I O N S S H O U L D B E M O R E F R E Q U E N T T H A N S U G G E S T E D B Y T H E M A N U FA C T U R E R . A L S O, I T M AY B E A D V I S A B L E T O P E R F O R M T E S T S O N T H E O I L T O D E T E R M I N E S E RV I C E A B I L I T Y, R AT H E R T H A N A U T O M AT I C A L LY R E P L A C I N G T H E O I L .

The following sources will help in the development of PM

procedures:

2 . PLANT EXPERIENCE: - MECHANICS WHO WORK ON EQUIPMENT AND THE

OPERATORS WHO RUN IT CAN HELP DEFINE PM THAT MIGHT BE SPECIF IC TO THE EQUIPMENT'S ENVIRONMENT.

- WORKING TOGETHER , THEY OFTEN DISCOVER PM PROCEDURES THAT WOULD NOT OTHERWISE BE OBVIOUS.

- THE OPERATOR MIGHT BE AWARE OF A SPECIF IC SYMPTOM THAT PRECLUDES A PROBLEM. THE MECHANIC MAY BE ABLE TO RELATE THE SYMPTOM TO A FAIL ING COMPONENT.

The following sources will help in the development of PM procedures:

- THE DEVELOPMENT OF A PM PROCEDURE IS NOT COMPLETE UNTIL IT HAS BEEN PERFORMED AND CORRECTED.

- SOLICIT THE REMARKS OF PERSONS REQUIRED TO PERFORM THE PROCEDURE. IF THE PROCEDURE DOESN'T WORK FOR THEM, IT WON'T BE A SUCCESSFUL EFFORT.

- ADDITIONALLY, REACTING TO THEIR COMMENTS AND GIVING THEIR EFFORTS VISIBILITY WILL IMPROVE INVOLVEMENT IN THE PROGRAM.

The following sources will help in the development of PM

procedures:

1. AFTER TH E PR OCED UR E IS COR R ECTED , TH E FR EQUEN CY OF TH E PM MAY H AVE TO B E AD JUS TED .

2. I F A FA ILU R E H AS OCCU R R ED B ETWEEN PM IN S PECT ION S , TH E PM PR OCEDU R E AN D FR EQU EN CY S H OUL D B E R EV IEWED. L ESS OBV IOU S , B U T EQUALLY IMPORTAN T, I S TH E IDEN T IF ICAT ION OF PM WOR K WH ICH IS PER FOR MED TOO OFTEN .

3. AS A R UL E , AN EFFECT IVE PM PR OG R AM WIL L G EN ER ATE TH R EE COR R ECT IVE ACT ION WOR K OR DER S , OR ON -TH E -S POT R EPA IR S , FOR EVERY TEN IN S PECT ION S PER FOR MED. I F A PR OCEDUR E DOES N 'T S EEM TO B E PAY IN G OFF IN TH IS WAY, TH E T IME B ETWEEN IN S PECT ION S S H OU LD B E EX TEN DED.

4. FR EQUEN C IES L EFT UN COR R ECTED U N DER MIN E TH E CR ED IB IL ITY IN TH E PR OG R AM FOR TH E PER S ON S PER FOR MIN G TH E WOR K AN D TH OS E B EN EF IT IN G FR OM TH E EFFORT.

Preventive Maintenance Frequency

- O N C E YO U R F I R S T P R O C E D U R E I S O F F A N D R U N N I N G ,- R E T U R N T O YO U R L I S T O F E Q U I P M E N T C A N D I D AT E S F O R P M W O R K

A N D A D D N E W E Q U I P ME N T A N D P R O C E D U R E S T O T H E P R O G R A M. WH E N I S T H E P R O G R A M C O MP L E T E ? M A N Y R I G H T M I N D E D I N D U S T R I A L O R G A N I Z AT I O N S H AV E A D O P T E D T H E S E E MI N G LY U N AT TA I N A B L E G OA L O F " A L L A C C I D E N T S A R E P R E V E N TA B L E . "

- T H E Y K N O W T H AT T H E G OA L H E L P S P E O P L E F O C U S O N T H E WAY S T O P R E V E N T A C C I D E N T S , I . E . R E D U C I N G U N S A F E C O N D I T I O N S A N D U N S A F E A C T S . A S I M I L A R A P P R OA C H S H O U L D B E TA K E N WI T H R E S P E C T T O E Q U I P M E N T FA I LU R E S I N A P L A N T.

- F O C U S I N G O N A G OA L S U C H A S " A L L FA I LU R E S A R E P R E V E N TA B L E " , O R " A L L D O W N T I ME I S P R E V E N TA B L E " , L E A D S P L A N T P E R S O N N E L T O I D E N T I F Y T H E C AU S E S O F FA I LU R E S A N D D I S C OV E R WAY S T O R E D U C E T H E M. C H A N C E S A R E YO U W I L L N E V E R I D E N T I F Y A N D S O LV E A L L YO U R E Q U I P M E N T P R O B L E M S , B U T WI T H YO U R E Y E O N T H E G OA L YO U ' L L B E H E A D E D I N T H E R I G H T D I R E C T I O N .

Preventive Maintenance Frequency

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