Preventive Maintenance

Effective Preventive Maintenance

Posted by on Jul 30, 2013 in Preventive Maintenance | Comments Off on Effective Preventive Maintenance

We are in a time when business decision making has to be prudent, information based, and aligned with organizational goals. This holds true in every department and category within an organizational structure, and within the key elements of cost-savings initiatives. Many organizations are now using computerized maintenance management systems (CMMS) not only as a record keeping resource of preventive maintenance activity, but as an expense reduction resource. A CMMS can be very effective in the control of operating budgets for maintenance departments and it helps create a well performance-based preventive maintenance management system. A Win-Win Situation – Reducing Maintenance Cost while Increasing Productivity A CMMS provides a company’s maintenance department with the opportunity to increase overall productivity and reduce cost while positioning the department to be a cost management value to an organization. Preventive maintenance (PM) planning and measures should include an organized user-friendly manageable system. A CMMS addresses the organizing of planning, tracking, identifying maintenance “bottlenecks”, and the deliverables needed for the optimization of equipment operations and the fulfilling its projected life span. It can also be used to project planned replacement intervals for equipment before equipment failure, greatly reducing the chance of an unplanned replacement in more costly conditions. Preventive Maintenance in a CMMS environment can effectively change the value of a PM program into the reality of increased bottom line profits through the efficiencies of productivity gains and a vast improvement in equipment downtime.”Raising the Bar” through an effective CMMS creates a maintenance department that is well integrated and aligned with other organizational goals. Well implemented systems generate a healthy Return on Investment (ROI). A qualitative example could be in sales. Presenting sales staff with a record of no lost sales due to product shortage resulting from equipment failure, is an added plus to the business and the customer...

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Preventive Maintenance – A Brief Introduction

Posted by on Jul 30, 2013 in Preventive Maintenance | Comments Off on Preventive Maintenance – A Brief Introduction

’Preventive Maintenance’ is often a misunderstood term. It is often confused with other terms such as predictive maintenance, reliability centered maintenance, and condition monitoring. This article will set the record straight on what preventive maintenance is exactly. All around the world, a good number of maintenance departments still work with systems largely based on corrective maintenance. This basically refers to the act of repair. In other words, these maintenance departments work by simply fixing equipment whenever it breaks down. The problem with this approach is that it does not allow for a great deal of planning in the maintenance department since nobody really knows what the next work order will consist of, and when and where it will be. This information only becomes available when a failure or breakdown occurs. As a consequence, department efficiency is sacrificed leading to higher costs. Another problem with corrective maintenance is that when equipment becomes faulty, the production process is disturbed thus leading to less output from the operations department. This results in even more money loss. Preventive maintenance is a system which offers solutions to these problems. It normally involves any work that helps to prevent equipment failure and hence, helps extend asset lifetime. Many times, this type of maintenance is time-based. However, preventive maintenance need not be time-based and preventive checks can be carried out on what is referred to as subjective condition monitoring. This means that when the maintenance technicians sense that equipment requires maintenance, then this can be either scheduled for later on or be carried out immediately. Some examples of preventive maintenance jobs include checking asset alignment, balancing, lubrication, vibration and voltage. More examples include replacing parts, replacing equipment with fixed life-times, equipment cleaning, and equipment installation procedures. To help with setting up efficient preventive maintenance systems, many companies today make use of computerized maintenance management systems (CMMS). These are software applications that help maintenance departments manage their equipment and employees. For more information on CMMS, read What is a CMMS? Why is it...

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3 ways to improve Health and Safety in your Maintenance Department

Posted by on Jul 30, 2013 in Preventive Maintenance | Comments Off on 3 ways to improve Health and Safety in your Maintenance Department

This is the first article in a two-part series about how to improve health and safety practices in your business. The health and safety issue should be prioritised and given utmost attention, regardless of the industry. In this article we are discussing health and safety with regards to manufacturing industries. A company’s most prized asset is its workforce. Therefore, human resource planning and maintaining high quality standards, are necessary for businesses to protect the health and lives of their employee at the place of work. One of the functions of a Computerized Maintenance Management System (CMMS) is to ensure that certain standards are kept, both by the employees individually and also by the company as a whole. Companies that are serious about the safety of their employees maintain quality standards minimizing any possibility of accidents happening at the place of work. This article will be concerned with a brief discussion on creating a safe environment on the place of work. Attention will also be attributed to how CMMS software can contribute in this regard. 1. Identifying areas of danger Keeping records of past workplace incidents is important as it serves the purpose of helping notice any patterns with workplace incidents. For instance, if within the last two years, there have been three incidents with the electricity generator, resulting in a number of injuries, a thorough investigation of the situation is then necessary. The argument that the past is not always a good indicator for future decision making is very much debatable in the context of health and safety. This is completely understandable. If accidents are not catered for they will continue happening in the future, in the process jeopardizing the health of the companies’ employees. CMMS software is a useful tool that can be used to identify areas of danger. Using such systems helps you automatically keep a record of all machine breakdowns, and therefore makes it easier to avoid situations which might threaten workers’ safety. Furthermore, recent advancements in reliability centred maintenance and condition monitoring, such as vibration analysis and oil analysis, it has now become easier to monitor the quality of operation of machinery. 2. Standard operating procedures Developing Standard Operating Procedures is one of the most critical exercises for any maintenance department. Having a safety program is crucial. A safety program, for instance, ensures that every work order issued by the CMMS has instructions describing the necessary safety precautions that need to be taken to ensure that the maintenance guys can perform their duties with minimal danger necessary. These instructions should ideally be pre-established before CMMS implementation so that employees get accustomed to them. Clearly stated instructions are needed as they help reduce confusion and uncertainty, and as a result create a better workflow and productivity. For example if an accident is reported in Area B1L2C3 in a manufacturing plant, one will look for the operating procedures in practice at the time of the accident. Having the safety procedures written down also protects the company from any blame in case of injury. If it is found that an accident occurred because an employee did not follow such procedures, the firm escapes any liability provided that it provided the employee with the necessary tools needed to carry out the task safely 3. Safety priority The equipment of the firm is given an importance rating. This is called the ‘critical value.’ It depends on the importance of the asset to the firm in comparison to other equipment. This critical value is determined by the user, and many times it depends on the role the equipment plays in the production process, the amount of constant preventive maintenance it requires, the level of danger risk that it places the employee in the case of a fault, and so on. This is very relevant for good health and safety practices. In addition, if machines are not checked on a regular basis; they might act as a threat to an employee’s safety. Injuries to the workforce result in more production stoppages, and lower worker morale. Maintenance criticality should not be measured just...

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