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The article outlines a comprehensive 14-step process for optimizing preventive maintenance (PM). This methodical approach ensures a thorough and effective PM optimization process, aiming for continuous improvement across assets and functional areas.
Step 1: Establish a baseline using current metrics or data from maintenance and production/operations.
Step 2: Identify which asset/functional area the PM optimization will be executed.
Step 3: Identifying a cross-functional team (operator, maintenance tech, reliability engineer, planner, etc.).
Step 4: Establish expectations from everyone engaged in this process.
Step 5: Define the end goal of this process.
Step 6: Define roles and responsibilities for all members of the PMO team.
Step 7: Define how you'll measure if the PM optimization process has been effective or not.
Step 8: Present copies of PMs to all parties.
Step 9: Review equipment history for the past 30, 60, and 180 days.
This includes:
- Root causes of critical breakdowns
- PM labor hours vs. EM/urgent labor hours
- PM compliance vs. OEE
- Rework
Step 10: Review current PMs and PdMs for these reasons:
- PM procedure may need to be rewritten
- Training may be required
- PM frequency may be inaccurate and need adjustment
- Checking if equipment is in "maintainable condition"
Step 11: Rewrite PMs or write new PMs (ensure they are repeatable).
Step 12: Monitor and measure to ensure new PMs are effective and adjust as needed.
Step 13: Post results for all to see.
Step 14: Once concept has been proven move to the next asset/area.
PM Optimization Results Example:
About the Author
Ricky has over 30 years’ experience working as Maintenance and Reliability Professional for companies such as Exxon Company USA, Alumax Mt Holly, Kendall Company and the US Army. In addi...
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