Planned Maintenance

How often should PM strategies and tasks be reviewed?

The question is often asked “how often should PM strategies and tasks be reviewed?’"Here are 3 processes an organization should have in place to support PM reviews.

Root Cause Analysis  review:  Each time an RCA is performed on failed equipment a review of the maintenance strategy should also be performed.  The review of the maintenance strategy including the PM tasks should determine if a task exists that is supposed to prevent or identify early the incipient failure that ultimately led to the failure of the equipment. 

If a task exists it should be determined if the task was performed properly.  If the task was performed properly then the task should be changed as its ineffective.  If the task was not performed properly then training should be provided to so that the task will be performed properly in the future. If no task exists then one should be developed and added to the PM procedure and the maintenance strategy updated.

Reliability Matters: Planned Maintenance Vs Reactive Maintenance

Reliability matters, whether it is in your personal life or on the factory floor.  It is generally assumed to cost 2 to 5 times more for breakdown maintenance as the same job in a planned, scheduled environment. This is a truth I was recently reminded of.

During a 600-mile drive to a family reunion my truck's fuel pump failed.  The cost of repair and towing was $781, even with a few towing miles paid by AAA. The lost-time on the trip was 5 hours.  All in all, it was a pretty "fortunate failure" and I was able to coast to an off-ramp, and roll right into a parking lot when the truck died.  In addition to that good fortune a nearby garage could get me in within two hours of the breakdown and the parts were available the same day. Another garage I called had no time available for almost a week.

To calculate the cost of this breakdown failure in comparison to a scheduled failure, I did a search and found that the fuel pump and filter if purchased at a local parts store would total $275.  The labor for the job was about 3 hours and they kept my fuel in the tank.

Total Productive Maintenance Implementation: The Importance of Communication

A crucial element to effective adoption and implementation of Total Productive Maintenance (TPM) is clear and honest communication. To support your TPM implementation effort consider one-on-one meetings with your maintenance crew to communicate the importance of TPM elements: operator care, planned maintenance...etc.  

By sitting one-on-one with your crew you can answer questions directly and discuss the importance of the initiative. Just as important as expressing the virtues of TPM is getting a feel for the level of maintenance support and having the opportunity to answer any questions that the crew may have. It will pay huge dividends to face issues upfront and convert possible skeptics into TPM supporters.



Writing an Effective PM - Five Simple Steps

Each and every PM (Planned Maintenance) task should include all 5 steps to ensure that the work is completed as required.

Planned Maintenance - Image

  1. What is to be done? Start with an action word (e.g. Lubricate, Listen, Touch, Feel, Obtain readings)
  2. How is it to be done? Describe in detail how you want the procedure carried out. Is there a particular way to perform the procedure? Is there a particular order in the way the procedure should be performed? Do instruments have to be in a particular position to obtain the correct reading?
  3. What is acceptable? If the craftsman is going to meggar a motor, at what reading should the craftsman be concerned? If the craftsman is performing vibration analysis, is there an absolute reading that is unacceptable?
  4. What course of action should the craftsman take if the results are unacceptable? A motor that meggars at 1500 ohms should not be started for any reason. A belt at start-up that slips so badly it releases a cloud of smoke and burnt rubber should not be left in running condition. If the lubricant level is below a certain point, it must be replenished. In many cases the craftsman should contact his immediate supervisor if the condition is outside acceptable limits. In other cases, just noting the anomaly on the PPM work order is sufficient.