It teaches you how to plan the whole transition, implement a preventive maintenance strategy, set up best practices, train your team, and how CMMS enables and supports this transition. Corrective maintenance is a maintenance task performed to identify, isolate, and rectify a fault so that the failed equipment, machine, or system can be restored to an operational condition within the tolerances or limits established for in-service operations.
Simplified, corrective maintenance focuses on diagnosing and fixing broken assets. Preventive maintenance or preventative maintenance is work that is performed regularly on a scheduled basis in order to minimize the chance that a certain piece of equipment will fail and cause costly unscheduled downtime.
Preventive maintenance is hence performed while the equipment is still in working condition. To help you accomplish this goal we have put together a simple step-by-step guide on how to convince your manager and make the switch to preventive maintenance activities. If this is your first time making a preventive maintenance plan, we suggest that you start by scheduling preventive maintenance on your most critical assets. Additionally, this will give you and your team some breathing room to adjust and transition into a proactive maintenance mindset and workflow.
When trying to determine which assets to select for your preventive maintenance plan, ask yourself the following questions:. Equipment manufacturers have a plethora of statistical data from in-house testing and field tests done by customers. The manuals they provide often contain schedules for necessary maintenance, the usage of critical spare parts, and basic maintenance work instructions.
Even if you are not using a CMMS computer maintenance management system right now, you will hopefully have some sort of maintenance log available. Look at what kind of failures did the asset you put on your PM plan experienced in the past and how often.
From that, you can roughly extrapolate what kind of preventive work you can schedule and how often to prevent some of those failure modes in the future. As a proactive maintenance manager, some insights you can only get by talking to the people that are turning the wrench and that are in the contact with the machines daily.
While he was able to get the machine running, some components are currently experiencing additional wear and tear. Because of that, you need to schedule regular inspections of those components until those spare parts arrive and the problem is resolved.
Here is another resource for the frequency of preventive maintenance inspections. If everything went according to plan, you now have the list of all the needed preventive maintenance tasks and a general idea of how often you need to perform each of those tasks on a particular asset.
All that is left is to enter the data into your maintenance planning tool hopefully a CMMS , assign your tasks to the correct people, and add a priority and due date to ensure the whole team is on the same page. If you want to see an actual example of a preventive maintenance plan, we have one just a few scrolls below.
The good news is that this challenge is easily solved, especially if you are using a modern CMMS like Limble. You just need to:. Maybe it could still operate without failures with less preventive work spent on it.
Asset experiences regular failures despite regular check-ups and other preventive measures? It is possible to schedule even more preventive work on it after you investigate what those breakdowns were and what caused them. Lastly, you have to be aware that your initial PM schedule will never be perfect — and that is perfectly fine.
If that is indeed the case, then it is time to repeat these steps and expand your preventive maintenance program to the rest of your assets that will benefit from it. It looks like you are using a personal email address. Please use your work or. Now it is time to see what kind of regular preventive work needs to be done on this asset to ensure it works in peak operating condition and minimize any chance for an unexpected failure.
While we are going to take these recommendations at a face value, you should not. Before you use this data to create a preventive maintenance schedule, talk with your technicians, and look at any available maintenance logs and reports. Find out what is the current condition of the asset in question, and use that information to adjust the PM schedule accordingly. Now that you have the list of needed preventive maintenance tasks, it is time to assign them to your maintenance team and let the magic happen.
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Today, there are a lot of software on the market. Spend some time to understand your requirements, conduct extensive market research, choose a program with care, and collaborate with the vendor to establish a training program. All of the aforementioned steps will help you create a preventive maintenance program from scratch. Arguably, you should do this before actually creating your program. In other words, a well-designed program can have a positive impact on the bottom-line of the company.
All of these benefits should be clearly communicated to all of the key stakeholders in the organization. This will help you gain company-wide support and fast-track the implementation process. At the end of the day, you know your organization and its culture better than anyone else. Think of an appropriate way of introducing your preventive maintenance program.
You can also consult your CMMS vendor. Most modern vendors offer on-site training, along with educational material. Additionally, make sure that you gather feedback from your maintenance supervisors and use appropriate metrics to gauge the effectiveness of training. There are immense benefits of preventive maintenance. A successful preventive maintenance program is one that is carefully designed, formally implemented, and consistently measured.
Compromising on the upkeep of such assets can result in costly repairs, unnecessary delays, or worse, fatal accidents. With proper implementation, you can ensure that every dollar you spend on your program is put to good use.
A program that lacks planning could end up burning hundreds of thousands of dollars. Finally, with the help of a solid preventive maintenance program, you can increase the longevity of your critical equipment.
This includes everything — from movable assets to fixed systems like HVAC. These are the type of immediate cost and labor savings that a preventative maintenance program can ensure that you will see almost immediately when you put a preventative maintenance program in place. The price of oil for a front end loader alone can quickly drain your vendor credit account.
If you catch a breakdown in the early stages, you can prevent major parts from being destroyed. The last thing, any heavy equipment owner needs is an OSHA recordable. Not only are you risking such an occurrence by not properly maintaining your heavy equipment, but when OSHA shows up on-site, they will expect to see every maintenance record that you have on that piece of equipment. When you put a reliable preventative maintenance program or a CMMS into place, you arm yourself with records that are indisputable, and with the knowledge that you did everything possible to protect your employees from the harm that can come when they run faulty equipment.
We all want to get the maximum mileage out of our heavy equipment.
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