Objectives

After this training you will be able to:

Define a Preventive Maintenance (PM) system

Recognize reasons and need for a PM system
Define advantages of a PM system
Recognize risks of a PM system
State the law of PM
Describe the PM execution process
Describe ways to fix data absence
Define ways to motivate PM workers.

What is Preventive Maintenance?

Preventive maintenance is a schedule of

planned maintenance actions aimed at the
prevention of breakdowns and failures.
The primary goal of preventive
maintenance is to prevent the failure of
equipment before it actually occurs.
Designed to:
Preserve and enhance equipment reliability
by replacing worn components
Ensure machine failures are not the cause for
workplace mishaps.

PM Requirements

A written preventive and predictive maintenance

system must be in place
Equipment must be replaced or repaired on a
schedule, following manufacturers
recommendations
Documented records of maintenance and repairs
must be kept
The system must include maintenance of hazard
controls such as machine guards, exhaust
ventilation, mufflers, control circuits and devices,
etc.

Need for PM System

A PM system aligns with a

safety management
program to:

Prevent injuries caused by

malfunctioning equipment
Increase automation
Reduce losses due to
production delays
Improve quality
Just-in-time manufacturing
Provides a more organized
work environment.

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Advantages of a PM System

Some advantages of a PM system include:

Reduced production downtime

Conservation of assets and increased life
expectancy of assets (both machine and human)
Ensuring all equipment safety features are
functioning properly
Reduced cost of repairs by reducing secondary
failures
Quality products
Identification of equipment with excessive
maintenance costs

PM Program Risks

PM program risks could

include:

Damage to adjacent equipment

during a PM task
Damage due to an error in
reinstalling equipment into its
original location
Damage due to the installation of
new parts.

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The Law of PM Programs

The higher the value of plant assets and
equipment per square foot of facility, the
greater will be the return.

Things To Consider

Things to consider after completing a

maintenance operations:

Ensure equipment meets manufacturers

specification
Review job hazard analysis (JHA) to ensure
equipment alterations or equipment maintenance
did not introduce new hazards
Conduct machine checks to ensure all features,
especially safety devices, are functioning properly
Ensure employees are aware of any changes to
equipment and/or operating procedures.

A Successful PM System

Three keys for a successful

PM system:

Scheduling: Should be
automated to the maximum
extent possible
Execution: Should be done
before an actual break down
occurs
Quality: Should have a formal
process for checking the quality
of repairs.

PM Focus

PM focus should be on:

Cleaning
Lubrication and inspection
Correcting deficiencies
Operation of safety devices .

Pre-determined part
replacement should be
minimal and done only
where evidence clearly
indicates wear-out
characteristics.
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Data Absence

When PM data is missing

capture techniques should
look at:

Structural/facility
Age exploration programs
Statistical analysis
Safety inspection data.

Cost should not be a

primary factor in deciding
against data collection for
a PM system.
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Preventive Maintenance Workers

Ways to motivate your PM workers include:

Establishing effective training programs
Establishing inspection and preventive
maintenance as a recognized, important part of
the overall maintenance program, including
follow-ups
Assigning competent, responsible people to the
preventive maintenance program
Setting high standards
Publicizing reduced costs with improved up-time
and revenues and employee safety, which are the
result of an effective preventive maintenance
system.

Summary
In this presentation you learned about:

Preventive Maintenance Program components

Reasons for the PM system
Advantages of a PM system
PM risks
PM after action items
Successful PM system
PM focus
Ways to motivate PM workers.