What are the main objectives when implementing a preventive maintenance program? In general, it is finding ways of maximizing equipment’ shelf life, assuring their availability and reliability, preventing downtime, at the same time that keeps the maintenance costs under control. However, between the general concept and the implementation of the program, there is a big distance. Know what are the main steps to count on a preventive maintenance program that keeps the asset condition as close as possible to the original.
1 – Assess the condition of all your assets
In first place, it is necessary to know the asset and its criticality, assessing its actual condition, the effort to which it is submitted and the history, to set the probable time when the failure will happen. Of course, it is not possible to establish an exact date when an equipment will fail, but analyzing its performance you can reduce this probability previously programing the maintenance.
The survey of the real condition of the asset must identify and record:
- Number of failures, number of small stops, work accidents rate, downtime cost
- Equipment’s performance
- Setting the failures level – progressive reduction of failures
- Setting maintenance goals
2 – Start the elaboration of a preventive maintenance program
This plan will assure the continuous quality of all the services, preventing failures and improving the production cycle, analyzing the consequences of a failure, such as detecting this failure and with which antecedence this failure can be detected.
All the preventive maintenance program operations must meet 3 requirements – applicability, efficiency and profitability. An operation is applicable if it can be implemented, it is efficient if it reduces the failures index and it is profitable if it improves the production.
The maintenance periodicity must initially follow the manufacturer’s instructions, but adverse environmental conditions of use may interfere with the schedule.
The maintenance actions are divided in two types.
One is based on time, that foresees replacing or restoring, in previously established intervals, pieces and components presenting more chance of failure according to their time of use. Once the time limit was reached, these conditions are executed apart from the status of the part at the date of the replacement. However, the actions based on time will only be efficient when there is a relation between the age of the component or piece and its failure probability.
Another way of assessing the need of maintenance actions is the one based on the condition, which takes in to account the periodical inspections results. The analysis of the history of these inspections allows to detect failures and anomalies signs in pieces and compounds from all the machines and equipment. The objective is monitoring the possible failures and act before they happen.
3 – Document all the actions
All the actions of the preventive maintenance program must be documented so that they are easily understood, using more drawings and schemes instead of text. Make it very clear how and why the inspection must be performed.
Besides the step by step of the maintenance actions, the document must contain the following information:
- Services to be performed
- Date when the services will be performed
- People in charge of the services execution (name, position, function and contact)
- Risks involved in the tasks
- Necessary resources for the services execution (spare parts, tools, materials)
- How much time will be spent in each service?
- Cost of each service, cost per unit and total cost
- Necessary machines, devices and tools
4 – Program services in an automatic and optimized way
Integrate all the assets data (operation, failures, maintenances already performed) in a solution for the planning and programming optimization of maintenance services. The system must simultaneously analyze the production needs, the maintenance priorities, the planning guidelines and the use restrictions. From this information, the system provides a series of suggestions to optimize the programming and the execution of the services, contributing to reach the excellence in productivity, operational efficiency and safety.
5 – Register all the actions
Reports must be elaborated after each step of the preventive maintenance program and the information entered in the automatized planning system. These reports serve to analyze mistakes and successes, register replaced spare parts, expenses with spare parts, lubricants etc., and the average runtime of tasks execution.
Atech offers, through OKTO platform, a set of solutions turned to the asset management area able to understand companies from different sectors with dynamic tools, able to operate in a global level. One of these resources is the Solution for Maintenance Planning and Programming, providing an updated resources system, as well as the execution management of the most critical activities. Know more on Atech’s solutions for Asset Management and know how we can help you to manage assets in an efficient and reliable way.