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Proactive Maintenance – Creating and Optimizing CBM, PM and PdM 

Are you doing too much time based maintenance? So many PMs in a week that you can't get them done? Yet, the equipment reliability continues to decline? Failures still happen?
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Typical challenges with your CBM, PM and PdM efforts

Reactive organizations respond to failures, running from one breakdown to the next. Their equipment dictates their days.

It's not uncommon to find preventive maintenance procedures created as knee jerk reactions to failures. Other than the OEM manual, often there is no basis for the work activities. Most procedures don't address any of the likely failure modes for the asset.

Preventive maintenance (PM) provides control over your assets, helping you to avoid failures by identifying and correcting them before they occur. PM programs must balance asset availability with maintenance needs to minimize downtime while prolonging equipment life though, in order to maintain productivity and profitability.

Predictive maintenance (PdM) lowers costs and increases overall reliability when done properly. But PdM can be expensive and requires experience and skills that many organizations lack. Read more
Here are some signs that your organization may need to implement a PM and/or PdM program or to improve your efforts.

  • PM work orders are vague. Assigning a technician to “check the pump” doesn’t ensure success because it doesn’t define the desired actions or results.
  • Grease guns have become deadly weapons. Capable of putting out 10,000 to 15,000 pounds per square inch of pressure, grease guns can easily over lubricate equipment if you don’t use them right.
  • Your Computerized Maintenance Management System (CMMS) reports don’t show if a corrective work order was raised from a PM or PdM inspection.
  • You want to invest in condition-based monitoring but don’t know how to begin.
Interestingly, organizations vary widely in their use of preventive (PM) and predictive maintenance (PdM). When you look at one end of the spectrum, some organizations are still of the mindset that preventive maintenance is an overhaul of the equipment and these overhauls occur automatically on some time basis.

Organizations on the opposite end of the spectrum rely heavily on PdM to lower costs and increase overall reliability. Some of these organizations derive as much as 70% of their corrective actions from PdM monitoring and trending.

Regardless of where your organization is on the spectrum, People and Processes can assist you in developing the right maintenance strategies for your equipment using Reliability-Centered Maintenance methodologies.

Solutions to solve the problems with condition based, preventive and predictive maintenance approaches

If you don't tell your team what to do, how will you know when it has been done? Or whether it worked?

When you ask your people to check your equipment and processes you should explain what they should look for so that they can identify and prevent possible failures. Require them to enter a value wherever possible—a pressure, a temperature, a thickness, a vibration level—something quantifiable.

You should also test, evaluate and refine your programs for preventive maintenance and predictive maintenance to ensure their effectiveness. Control costs by managing the use of proactive technologies and using alternative PdM methods that are less expensive but equally efficient whenever possible. Read more
Here are some additional ways to improve reliability within your organization by optimizing your PM and PdM programs.

  • Audit completed PM work orders to see if they were well planned and executed.
  • Correct your lubrication practices. (Studies have shown that 60% to 70% of fires are induced by improper lubrication.)
  • Designate it in your CMMS if a corrective work order is raised from a PM or PdM inspection so that you can relate it back to that inspection.
It's not so much about the work that was done. You really want to know whether your PM and PdM programs work.
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A few ways we can guide you with CbM, PM and PdM program activities

People and Processes can help you create a proactive organization in which preventive and predictive maintenance increase reliability by preventing failures.

Program Development
Organizations that lack sufficient resourcing or knowledge of best practices in maintenance and reliability ask us to develop their entire PM/PdM programs. Read more
From setting goals like reducing spare parts costs and decreasing downtime to writing procedures for your equipment, People and Processes cultivates proactive reliability-centered maintenance cultures built upon efficient PM and PdM programs.

We also create PM processes like for writing and scheduling work orders (WO) and lubricating your equipment. We help you measure the effectiveness of our efforts as well by establishing and tracking key performance indicators (KPIs) like maintenance labor hours and materials by WO.

We can also implement predictive maintenance procedures using proven techniques and advanced technology.

Program Optimization
People and Processes can optimize your existing PM or PdM program so that you can minimize downtime without compromising equipment. Read more
Define parameters for corrective work orders based on condition monitoring results. Balance the expense of servicing an asset with the costs of shutting it down for maintenance. People and Processes helps you identify the optimum conditions and costs for your PM and PdM programs.

Best Practices Implementation Coaching and Mentoring
Learn and implement the principles, techniques, tools and processes for establishing best practices for preventive maintenance, predictive maintenance and condition-based maintenance. Read more
Here are just a few ways that People and Processes can help you avoid failures through PM, PdM and CBM.

  • Recognize the role of non-intrusive inspections in driving equipment reliability.
  • Know the types of predictive maintenance and when to apply the techniques.
  • Know Operations and equipment owner involvement.
  • Learn techniques for effective project startups and commissioning that build in effective equipment reliability and life-cycle costing.

Using our education and training to drive PM program improvements

For onsite activities, please review our education and training offerings on our Maintenance and Reliability Engineering pages that can be found at Maintenance Reliability Engineering page. This grouping provides more detail on developing the maintenance strategies for your assets.

To better understand how equipment fails and how to develop a maintenance strategy for your assets, consider our public venue course

Public - RCM2 Introductory course - 3 day

Regardless of whether your organization wants to implement or optimize a PM or PdM program, People and Processes can assist you in developing proactive maintenance strategies that allow you to avoid failures and control your assets.

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  How can we help you succeed? Tell us today!
 

Contact

PEOPLE AND PROCESSES, Inc.
P.O. BOX 460
Yulee, FL 32041-0460
Call us: 1-843-814-3795

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