Preventive Maintenance

Building effective PM programs:

Types of Preventive Maintenance:

Time-Based:
Service at fixed intervals:
- Calendar (monthly, quarterly, annual)
- Running hours
- Cycles or operations count
- Simple to schedule and track

Condition-Based:
Service when conditions indicate:
- Visual inspection triggers
- Simple measurements (temperature, pressure)
- Operator-reported issues
- More efficient but requires monitoring

Predictive-Directed:
PM informed by PdM findings:
- Vibration analysis identifies alignment need
- Oil analysis triggers change
- Combines PdM and PM benefits

Common PM Tasks:

Lubrication:
- Grease bearings
- Oil changes
- Automatic lubrication systems
- Lubrication surveys

Inspection:
- Visual condition checks
- Leak detection
- Wear measurement
- Safety device verification

Adjustment:
- Belt tension
- Chain alignment
- Clearance settings
- Calibration

Replacement:
- Filters (oil, air, hydraulic)
- Belts and seals
- Wear items
- Time-limited components

Cleaning:
- Remove debris and buildup
- Heat exchanger cleaning
- Sensor and detector cleaning
- Appearance for inspection

Creating an effective preventive maintenance program:

Equipment Inventory:
- Comprehensive asset list
- Criticality ranking
- Equipment identification
- Location mapping

Task Development:

Sources for PM Tasks:
- Manufacturer recommendations
- Industry standards
- Experience from failures
- Condition monitoring findings
- Regulatory requirements

Task Content:
- Clear description of work
- Required materials/parts
- Tools needed
- Safety precautions
- Estimated time
- Craft required

Frequency Setting:
- Start with manufacturer recommendations
- Adjust based on experience
- Consider operating conditions
- Balance cost vs. risk

Scheduling:

Scheduling Considerations:
- Production schedules
- Equipment availability
- Technician availability
- Coordination with operations

Compliance Tracking:
- Schedule adherence metrics
- Overdue PM alerts
- Completion documentation
- Continuous improvement

Optimization:

PM Effectiveness:
- Are PMs preventing failures?
- Reduce frequency if no findings
- Increase if problems occur between PMs
- Replace with PdM where appropriate

Task Refinement:
- Update based on experience
- Remove ineffective tasks
- Add tasks for discovered issues
- Adjust time estimates

Performing PM work effectively:

Work Preparation:

Parts and Materials:
- Kits pre-assembled for common PMs
- Material staging before shutdown
- Right parts, right quantity
- Quality materials

Tools:
- Tool lists for each PM
- Specialized tools available
- Calibrated instruments
- PPE ready

Information:
- Procedures available
- Equipment history
- Previous PM findings
- Safety lockout requirements

Execution:

Quality Performance:
- Follow procedures completely
- Don't skip steps
- Proper techniques
- Correct torque, settings

As-Found/As-Left:
- Document condition before work
- Document condition after work
- Enables trend analysis
- Identifies developing issues

Anomaly Reporting:
- Report findings beyond PM scope
- Generate follow-up work orders
- Photos of unusual conditions
- Communication to planning

Documentation:

Essential Records:
- Date and time
- Technician performing work
- Tasks completed
- Parts used
- Findings and observations
- Time spent

CMMS Entry:
- Complete work orders properly
- All fields populated
- Clear notes
- Asset history value

Feedback Loop:
- PM task improvements
- Procedure corrections
- Spare parts adjustments
- Training needs identified

PM skills are fundamental for maintenance careers:

Why PM Skills Matter:
- Most maintenance hours spent on PM
- Foundation for all maintenance work
- Develops equipment knowledge
- Builds systematic work habits

Using PM for Career Growth:

Learning Opportunity:
- Understand equipment operation
- Learn common failure modes
- Develop troubleshooting intuition
- Build comprehensive skills

Demonstrating Value:
- Quality PM work reduces failures
- Documentation shows thoroughness
- Initiative in improvements
- Foundation for advancement

Career Progression:

Entry:
- PM execution under supervision
- Learn procedures and equipment
- Develop basic skills

Developing:
- Independent PM execution
- Multiple equipment types
- Contributing to improvements

Experienced:
- PM program development
- Training others
- Optimization leadership

Leadership:
- Program management
- Metrics and reporting
- Strategic planning

Related Skills:
- CMMS proficiency
- Documentation quality
- Procedure writing
- Training delivery
- Continuous improvement methods

Certifications:
- CMRP includes PM program knowledge
- SMRP body of knowledge
- Manufacturer training
- Craft-specific certifications

PM excellence demonstrates professionalism and attention to detail that employers value highly.