Developing Your Preventive Maintenance Program
by Owe Forsberg
You are the new Reliability Engineer in a plant that currently lacks documented procedures to maintain the plant. You have been asked to develop preventive maintenance procedures (PM’s) for the plant and a target of 6 months to complete the project.
The plant has around 5,000 pieces of equipment. A corporate initiative to increase output and reliability of product deliveries is the reason for developing and documenting the PM procedures. The plant runs from 5/24 to 7/24 depending on the market demand.
Beside the issue with how to manage this as a project and using a CMMS to manage and maintain the procedures and history this article will focus on how to select your PM procedures in a practical way. Note that most PM procedures should focus on equipment at the component level like bearings, packing, impeller etc.
The following steps are required to develop your PM procedures:
- Divide equipment into components.
- How does the component work?
- How does it fail?
- What essential care does it need?
- Is the life of the component predictable or unpredictable?
- Does it have a Failure Developing Period (FDP)?
- Select the most cost effective maintenance method.
- Do maintenance on the run (OTR) or during shutdown (SD) of the equipment?
- Select objective or subjective (senses) method to check the condition?
- Develop your PM task.
- Select the frequency based on FDP
- Decide who is going to do the task on a regular basis.
- Transfer all the PM’s into your CMMS.