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Implementing a living Preventive Maintenance Program


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Hi all,

Creating a Preventive Maintenance (PM) Program is definitely not an easy task. Yet, ensuring it will be a cost-effective program today, next month, in one year time, or maybe in ten years time is as challenging as creating one from scratch.

Yes, that is correct. A cost-effective PM program today, may not be cost-effective tomorrow.

This is because things change. For instance, a chemical company might introduce a new formula. A mining company might be getting older and its ore is getting harder. A new product has just been released to the market. And the list goes on and on...

Yes, it happens. And when it happens, you usually will not have enough time nor information to ensure everything will be perfect.

For this reason, one of the biggest challenges for any Maintenance and Reliability Department, is to ensure that they have a living PM Program.

Implementing a living Preventive Maintenance Program:

1- Formal process - establish a formal process to ensure your PM is both periodically reviewed and also reviewed based on triggers (operational changes, unplanned failures, equipment redesign, etc).

2- Use data -   Data play a huge part on a reliability professional routine. On this topic it is not different. Use data available, such as increasing maintenance costs, production losses history. Use this data to create a theory.

3- Gather feedback - Once you have created a theory, validate such with operators and fitters. Ask them how often failures have been happening, how the components replaced look like when they come out of the machines. A simple form could be handy on this one by asking your maintenance team to answer questions on this form with their opinions based on what they see when doing your PM tasks (how the components look like, can this maintenance interval be pushed out, what could be improved) and attach it to the work order as part of the history - photos are highly helpful as well.

4- See with your own eyes -  In COVID-19 times this might not be easy. But in normal times, go out there and see with your own eyes what is being done, why, how and look for opportunities. When it comes to reviewing hundreds of maintenance plans at once it might be impossible. But if you keep an eye on those big ones and have a look at them periodically, you will be able to see new opportunities all the time.

 

Your turn!

When was the last time that you reviewed your PM program? What are the triggers used by your company or yourself? How do you ensure it is a living process?

 

Regards,

Raul Martins

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