01-Preventive Maintenance: Integrated Maintenance and Control

01- Preventive
Maintenance
Integrated Maintenance and
Control
Maintenance
All actions necessary
for retaining an item
or restoring it to a
specified condition.
2
Preventive Maintenance
All actions intended to keep
equipment in good operating
condition and to avoid failures by
providing systematic inspection,
detection, and prevention of
failures.
everything is going to fail
sometime
3
Preventive Maintenance, PM
PM can prevent those failure
from happening at bad time, can
sense when a failure is about to
occur and fix it before it cause
damage, and can often preserve
capital investment by keeping
equipment operating as well as it
did on the day it was installed.
Syahril Sayuti - 11 November
2012
Over 70% of organization with

physical assets only have a
rudimentary PM system or none at
all , why ?
Human nature makes us very reluctant
to invest time and resources in
something that might happen. The
PM approach is all about what might
happen.
What does top management want
from us (the maintenance function) ?
2012
The Maintenance Department

Mission
The mission of the

maintenance department is to
provide reliable physical
assets and excellent support
for its customers by reducing
and eventually eliminating the
need for maintenance
services.
2012
PM - Activities
Equipment checks, partial or
complete overhauls at specified
periods, oil changes, lubrication and
so on.
Recorded equipment
deterioration to know, when to
replace or repair worn parts before
they cause system failure.
Recent technological advances in
tools for inspection and diagnosis
2012
When Does Preventive

Maintenance Make Sense
1. The failure rate of the
component increases with
time, thus implying wear-out.
2. The overall cost of the
preventive maintenance action
must be less than the overall
cost of a corrective action.
2012
Four Dimensions of PM or
PdM
1.Engineering
2.Economic
3. People
Psychological
4.Management
2012
1. Engineering Dimensions
The task have to be the right tasks,
being done with the right
technique at the right frequency.
The have to detect or correct
critical wear that is occurring.
Analysis of statistic of failure,
uptime, and repair is included in the
engineering pillar of PM
2012
10
2. Economic Dimensions of PM or
PdM
The task must be

worth doing. The
PM activities must
make economic
sense.
2012
11
3. People Psychological
Dimensions of PM or PdM
the people doing the PM have to

be motivated to the extent
that they actually do the
designated tasks properly.
Without motivation, PM rapidly
becomes mind numbing.
2012
12
Management
Dimensions of PM or PdM cont.
PM has to be built into the

system and procedures
that control the business
and these systems must
be designed so that good
PM result.
2012
13
PM - Economic
One Time Cost:
Training and facilitation for every one to
change culture
For system (CMMS) to store information
Indirect system cost (wiring computer,
supplies, extra computer seat licenses,
etc)
Data entry labor for data collection
etc
2012
14
Costs of a PM System :
On going :
Labor for PM task list
Parts cost for task list
On going training
etc
2012
15
Cost of Breakdown
Production Cost :
Cost of lost production
Cost of airfreight of finished goods to costumer
Spoilage, contamination, or other compromise
to product
Loss of goodwill, loss of costumers or re-rating
from A vendor to a B vendor
Cost of overhead associated with original
assignment
Loss smooth function
2012
16
Cost of Breakdown
(continue)
Extra Maintenance Cost :
Extra cost due to core damage

Extra damage to associated parts and labor to
repair them Incoming airfreight.
Extra cost of outside vendor part and labor
Operator (crew) idle time
Extra travel time for mechanic
Extra repair time due to condition
Cost of all breakdowns * 70% > cost of PM
system
2012
17
Cost of all
breakdowns *
70%

2012
Cost of PM
system
18
Case study
Air compresor
1. Breakdown does not cause safety or
environmental exposures.
2. Compressor breaks down every 2 years on
average (or 50% probability each year)
3. Repair cost are $15,000 each time
4. Downtime costs are $ 45,000 per incident
Breakdown Cost :
($30,000) per year = 0.5<probability of failure
in 1 year> * ($ 45,000<down time costs> +
$15,000<repair costs)
2012
19
Compare the annual costs under the

breakdown plan with the costs of PM
PM Cost :
PM service compressor 12 times per year at a cost
of $ 1000 per service (part labor and downtime)
plus biennial scheduled overhaul costing $16,000
New probability of failure with PM : 1 failure in 20
year = 0.05.
US $23,000 = (($1000<PM cost> * 12<service per
year> + (.5<frequency of overhaul> * $16,000 <cost
of overhaul>)) + (0.05<new probability of
breakdown> ($45,000<downtime costs> +
$15,000<repair cost>))
2012
20
$ 30,000 * 70% = $21,000

(allowable)
current PM cost = $23,000
The PM cost is greater than 70% , so
more analysis needed. One thing that
would help is a redesign of PM system
to lower than $1000/month service
cost. Another improvement would be
to delay the biennial overhaul to 30
or 36 months if possible.
2012
21
Engineering Dimension
of PM
Engineering will delivery
the right task to the right
component, using the
right tool, at the right
frequency.
2012
22
Six misconceptions about

PM
1. PM is only a way of trying to determine
when and what will break or wear out so
that you can replace it before it does.
PM is much bigger than that. It is an
integrated approach to budgeting and
failure analysis, and permanent
correction of problem areas. It also
eliminates excessive of resources, and
can actually be seen as a way of life !
2012
23

PM
2. PM system are all the same. You can
just copy the system from the
manual or from your job and will
work.
PM system must be designed for the
specific equipment as set-up, age of
the equipment, product, type of
service, hours of operation, skills of
operators and many factor.
2012
24

PM
3. PM is extra work on top of existing
workloads and it cost more money.
PM increase uptime, reduces energy
usage, reduce unplanned events,
reduces airfreight bills, etc. There
are hundreds of ways PM saves the
organization resourses.

2012
25

PM
4. With the good forms and descriptions
unskilled people can do PM task.
Unskilled ( in manufacturing) people can
do some of the PM task successfully with
good training and clear form.
TLC activities (such as lubrication,
cleaning, or tightening bolts) can certainly
be done by trained but not maintenance
employees. Generally, inspection benefits
greatly from experienced eyes and hands.
2012
26

PM
5. PM is a series of task list and
inspection forms to be applied at
specific intervals (and obsolete)
All proactive maintenance activity is
part of PM. That includes the most
modern approaches such as
vibration routes, infrared surveys, or
condition based maintenance
checks.
2012
27

PM
6. PM eliminate breakdown
in the words of PM class PM cant put iron
into machine. in other words the
equipment must be able to do the job. PM
cannot make a 5 hp motor do the work of a
10-hp motor. Even with the most advance
PM there will still be breakdown from abuse,
misapplication, or accident. Some failure
modes (such as electronics failures) do not
currently lend themselves to PM.
2012
28
Task List
Is the heart of the PM
system, it remind the PM
inspector what to do, what
to use, what to look for,
how to do it, and when to
do it.
2012
29
Task List Cont 1
In its highest form, the

task list represents the
accumulated knowledge of
the manufacturer, skilled
mechanics, and engineers,
in the avoidance of failure.
2012
30
Task List Cont 2

The best task list could be design by
a variety of stakeholders including
OEMs(original equipment
manufacturers), skilled mechanics,
engineers, contractors, insurance
companies, governmental agencies,
trade associations, equipment
distributors, consultants, and
sometimes by large costumers.
2012
31
Task list-cont-3
All the task list item are
designed to perform one of
two functions. The two
function are extending the
life or detecting when the
asset has begun its descent
into breakdown.
2012
32
Life extension :
Clean
empty
Tighten
secure
Component replacement
Lubricate
Refill
top-of
Perform short repair
2012
33
Detection
Inspect
Scan
Look at part
Smell for
Jog
Take readings
Review History
Measure
Operate
Take sample for analysis Write-up
deficiency
Interview operator
2012
34
Common methods of
determining what PM policies
Original Equipment Manufacturer
(OEM) recommendations,
Requirements of codes and
legislation with in a jurisdiction,
what an "expert" thinks ought to
be done,
the maintenance that's already
done to similar equipment.
2012
35
Planned
Preventative
Maintenance PPM
2012
36
Planned Preventative
Maintenance - PPM
is a branch of Facilities Management and
can relate to any variety of scheduled
maintenance to an object or item of
equipment.
Specifically, Planned Preventative
Maintenance is a scheduled service visit
carried out by a competent and suitable
agent, to ensure that an item of equipment
is operating correctly and to therefore avoid
any unscheduled breakdown and downtime.
2012
37
Setting up a planned preventive

maintenance system
Equipment inventory
All equipment in the shop should be recorded
Maintenance task - definition

The work that must be done to maintain each
item of equipment in safe and reliable
operating condition must be defined.
These tasks can be established by consulting
the manufacturer's literature and product
information.
2012
38

maintenance system (Continue)
Establishing intervals of
maintenance
the frequency of the task must be
decided.
A heavily used item must be cleaned
and checked more frequently than one
which is used less often; however,
minimum standards must be set.
The frequency suggested in the
manufacturer's manual can be used as a
39
guide, but the
actual
usage should
2012

Personnel
Individuals who are qualified and available to do
preventive maintenance must be identified.
A list should be drawn up of personnel who are readily
available.
Once the personnel have been listed, specific
responsibilities should be assigned, perhaps in the form
of a work order, giving clear instructions for the task.
Each person should have a clear knowledge of his or her
responsibilities.
Job assignments must correspond to the training,
experience and aptitude of the individual.
2012
40

Reminder system
It may be necessary to develop a reminder
system, so that appropriate personnel are
notified when certain tasks are to be
performed.
The date that each item of equipment is
scheduled for its next preventive
maintenance should be recorded.
The administrator should look up in advance
the jobs that need to be done and draw up a
monthly or weekly schedule
2012
41

Special test equipment
People responsible for equipment
management and maintenance should have
at their disposal a range of test equipment
to check the correct functioning of
equipment
Surveillance
After the program has been set up, periodic
surveillance must be carried out to ensure
that the program well managed
2012
42

Technical library
A full technical library should be
available.
Installation and recommended spare
parts manuals, annotated with the
number of the corresponding
equipment, should be kept together with
electronic and component data books
and appropriate technical books.
2012
43

01-Preventive Maintenance: Integrated Maintenance and Control

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

01-Preventive Maintenance: Integrated Maintenance and Control

Uploaded by

Copyright:

Available Formats

01- Preventive

Over 70% of organization with

The Maintenance Department

The mission of the

When Does Preventive

The task must be

the people doing the PM have to

PM has to be built into the

Extra cost due to core damage

Syahril Sayuti - 11 November

Compare the annual costs under the

$ 30,000 * 70% = $21,000

Six misconceptions about

Six misconceptions about

Six misconceptions about

Syahril Sayuti - 11 November

Six misconceptions about

Six misconceptions about

Six misconceptions about

Task List Cont 1

In its highest form, the

Task List Cont 2

Setting up a planned preventive

Maintenance task - definition

Setting up a planned preventive

Setting up a planned preventive

Setting up a planned preventive

Setting up a planned preventive

Setting up a planned preventive

You might also like