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Maintenance Way

Preventive Maintenance Programs – A Low Cost Solution

You don't need to purchase those expensive software packages to establish a workable preventive maintenance program. Large companies with complicated equipment and huge spare parts inventories may find these canned programs advantageous and loaded with all the bells and whistles, but if you need a system that is just as effective and is quick to implement, easy to manage, and low cost, then why not create your own? You can create a successful program by using any spreadsheet software you already have, such as Excel or Works.

IDENTIFY YOUR EQUIPMENT

First, you will need to make a list of all of your equipment, maintenance tasks, etc. that you need to monitor and assign some unique type of identification to them. This can be a name, however, I prefer using a numbering code that tells me what type of equipment it is, where it is located (department, facility, etc.), and how many similar items I may have. With this code I will now be able to locate, monitor and maintain all of my equipment, while tracking costs and work performed.

DETERMINE REQUIRED TASKS

Next, you will need to determine the tasks or procedures needed to be performed on each piece of equipment and their frequency. Make sure to list every task that needs to be performed, no matter how simple or obvious it may seem. The hardest part of the whole program will be identifying these tasks.

A good place to start is with the manuals that came with your equipment. Round up all of your manuals and identify each of them with the same identification code you assigned to its respective equipment. The manuals will provide the essential maintenance tasks necessary to maximize your equipment life and also to meet the requirements of the applied warranties. These tasks will usually be the obvious ones such as checking lubricant levels or calibration procedures.

Another good resource will be your equipment suppliers. Your suppliers will either have the information you cannot find or they will be able to get that information from the manufacturers themselves. Many suppliers have a place on their websites where you can quickly access and download old maintenance and parts manuals. In addition, your suppliers may have information you were not aware of regarding warranty issues or newly recommended procedures to address known problems.

Finally, state, local and federal government agencies, entities, watchdogs, societies and the like will have information you will need in order to comply with codes and regulations that may be applicable to your equipment. For example: certain types of equipment or chemicals are strictly regulated and have set procedures for compliance. OSHA, the Federal Codes and Regulations, and the Department of Natural Resources are examples of places you may need to research in order to ensure you are meeting all of obligations.

DECIDE WHO DOES WHAT WHEN

Now that you know what it is that has to be done, you will need to determine when it needs to get done and who it is that is actually going to do it. The frequency of your maintenance tasks should be outlined in the same place you found the tasks listed. Determining who will perform each of the tasks is a little bit more difficult since there are many ways to handle it.

Will your maintenance workers be responsible for all the tasks? If so, you may need to hire more maintenance personnel. A common route is to assign the simple and menial tasks to your equipment operators. Tasks such as checking fluid levels or belt tensions can be performed at the beginning of a shift by almost anyone. Since the operators will typically be paid a lower wage than your maintenance workers, you can often times save money by having them perform these simple duties. You will also save a great deal of time when numerous operators simultaneously are checking their own equipment versus having one or two maintenance personnel making the rounds and checking each and every piece of equipment themselves. Save the more involved and time consuming tasks and repairs for your maintenance department. In some instances items may require outside services for certain intricate calibrations or the programming of controllers.

LIST THE DETAILS

Now is a good time to gather up all of the specific and pertinent details required to perform your maintenance duties. If someone needs to check something, they will need to know where that something is located. This is very important, especially if you are going to have non-maintenance people performing tasks. You will need to spell out exactly where they will find the fluid dip stick or sight glass, or where the fill opening is located. You certainly don't want someone adding antifreeze to the oil reservoir because the radiator is little low. You will need to state exactly what type of oil, etc. will be used. You will need to explain how much tension may be required in a belt or how much backlash is allowable between drive gears. Detailing specific part numbers of frequently replaced items such as air and oil filters is also a great idea.

CREATE A DATABASE

Take all of the information you have accumulated and put it into some useful form such as a Microsoft Works database or an excel spreadsheet. Use the column headings for the tasks, frequency, person, part numbers, etc. Use the row headings for the equipment identification codes. You now have all the necessary information in one place that can be easily updated or referenced in the future.

DEVELOPE YOUR FORMAL WORK PROCEDURES

Take the information from your database and create a worksheet or procedure which you can then post at each piece of equipment. Post the sheets in a conspicuous location where operators and maintenance personnel can easily find them and auditors can verify that the maintenance is being carried out. Include the maintenance items and other pertinent information along with a place to have each responsible person check off that they have completed their tasks. You can use initials, clock numbers, whatever works best for your organization. The check off area is essential to the success of your program. Without this accountability, you cannot ensure that the required tasks are actually being performed. It is a good idea to audit these procedures from time to time as well. I have seen where persons were signing off that they were checking fluid levels, but when the equipment refused to run one day, it was determined that the oil reservoir was nearly empty. No oil leaks could be found and subsequent discussions with the operator revealed that they were not checking the items, but were simply signing off that they were.

KEEP A LOG

Along with your database a very useful tool is a maintenance log of some sort. Again this can be a database or a simple spreadsheet. Keep track of the work performed, the date of the work, the costs involved, and the hours spent on the work. Tracking the hours will help you to more accurately determine your true costs for each piece of equipment, department, plant, shift, etc. A log is great for determining the problems or occurrences that you are experiencing in your shop. When you start to notice that you are performing the same tasks on certain pieces of equipment, you can use this information to schedule regular checks by adding the task to your database and equipment maintenance procedures.

You can also plan for the maintenance tasks that need to be performed. When you notice recurring items at consistent time intervals which cause downtime or require replacement parts that have long lead times, you can now schedule these tasks for a time when the equipment is not being run, reducing lost production. You can order parts just before they are needed, thereby eliminating the need to carry these parts in your inventory. You are now moving toward predictive maintenance. In addition to planning for your major maintenance tasks, you can now budget for them as well. Since your log alerts you to the recurring costs in addition to the tasks themselves, you now have the ability to predict your expenses for quarters, years, departments, plants, etc.; and you can use this information to determine your overhead with much more accuracy.

One more advantage of the log is the ability to determine when certain equipment has reached the end of its usefulYou don’t need to purchase those expensive software packages to establish a workable preventive maintenance program. You can create an effective program by using any spreadsheet software, such as Excel. life. You can tell, without any doubt, that a machine has become obsolete. When the annual maintenance costs for an old slow piece of equipment exceed the cost for a new state of the art piece of equipment, you can easily justify the purchase of the new equipment. So put together that maintenance program and start increasing your up time while decreasing your maintenance costs.

About the Author

Mr. Cavalluzzi is the founder and owner of CONSOLUTE, LLC engineering support and consulting services providing site search, industrial, manufacturing and design engineering support. His extensive background in engineering dates back to 1978 and includes the robotics, automotive, aerospace, metals and plastics industries.
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Maintenance Planning and Scheduling $48.95 This is a hands-on reference guide for the maintenance or reliability engineer and plant manager. As the third volume in the Life Cycle Engineering series, this book takes the guiding principles of Lean Manufacturing and Maintenance and applies these concepts to everyday planning and scheduling tasks allowing engineers to keep their equipment running smoothly, while decreasing downtime. The authors offer invaluable advice on the effective use of work orders and schedules and how they fit into the overall maintenance plan. There are not many books out there on planning and scheduling, that go beyond the theory and show the engineer, in a hands-on way, how to use planning and scheduling techniques to improve performance, cut costs, and extend the life of their plant machinery. * The only book that takes a direct look at streamlining planning and scheduling for a Lean Manufacturing Environment * This book shows the engineer how to create and stick to effective schedules * Gives examples and templates in the back of the book for use in day-to-day scheduling and calculations

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Computer-Managed Maintenance Systems $84.95 Effective resource management and reliable equipment are essential for optimum plant performance. Computer-Managed Maintenance Systems goes beyond the simple selection and implementation of a CMMS. It also defines the changes in infrastructure, management philosophy and employee skills that must be implemented to gain maximum benefits from the CMMS. The book is designed to address the information needs of all levels of plant management. In this new edition, the authors have added a chapter specifically on the latest technology, Application Solution Providers (ASP) that has revolutionized the way CMMS are used and the benefits they can offer to a business. This solution provides integrated software, hardware and networking technology along with Information Technology (IT) consulting services into an outsourced package. A new appendix on Key Performance Indicators has also been added. Comprehensive, practical guide that covers selection, justification, and implementation of an effective CMMS in any facilityAll levels of plant management will find useful information in this step-by-step guideIncludes a new chapter on ASP technologies

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Equipment Management in the Post-Maintenance Era $49.95 Recent advancements in information systems and computer technology have led to developments in equipment and robotic technology that have permanently changed the characteristics of manufacturing equipment. Equipment Management in the Post-Maintenance Era: A New Alternative to Total Productive Maintenance (TPM) introduces a new way of thinking to help high-tech organizations manage an increasingly complex equipment base. It also facilitates the fundamental understanding of equipment management those in traditional industries will need to prepare for the emerging microchip era in equipment. Kern Peng shares insights gained through decades of managing equipment performance. Using a systems model to analyze equipment management, he introduces alternatives in equipment management that are currently gaining momentum in high-tech industries. The book highlights the fundamental internal flaw in maintenance organizational setup, presents new approaches to replace maintenance functional setup, and illustrates a time-tested transformation and implementation process to help transition your organization from the maintenance era to the new post-maintenance era.Breaks down the history of equipment into five phases Provides a clear understanding of equipment management fundamentals Introduces alternatives in equipment management beyond the mainstream principles of maintenance management The book examines maintenance management logistics, including planning and budgeting, training and people development, customer services and management, vendor management, and inventory management. Supplying a comprehensive look at the history of equipment management, it analyzes current maintenance practice and details approaches that can significantly improve the effectiveness and efficiency of your equipment management well into the future.

Zen and the Art of Motorcycle Maintenance $68.51 High Quality Content by WIKIPEDIA articles High Quality Content by WIKIPEDIA articles Zen and the Art of Motorcycle Maintenance: An Inquiry into Values is a 1974 philosophical novel, the first of Robert M. Pirsigs texts in which he explores his Metaphysics of Quality. The book sold over 4 million copies in twentyseven languages and was described by the press as the most widely read philosophy book, ever. It was originally rejected by 121 publishers, more than any other bestselling book, according to the Guinness Book of Records. The title is an incongruous play on the title of the book Zen in the Art of Archery by Eugen Herrigel. In its introduction, Pirsig explains that, despite its title, it should in no way be associated with that great body of factual information relating to orthodox Zen Buddhist practice. Its not very factual on motorcycles, either. Author: Surhone, Lambert M./ Tennoe, Mariam T./ Henssonow, Susan F. Binding Type: Paperback Number of Pages: 76 Publication Date: 2010/09/09 Language: English Dimensions: 6.00 x 9.02 x 0.18 inches

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The New Low-Maintenance Garden (Paperback) $27.91 How often have you said "I'd love to be able to garden more; I just don't have the time." Modern life, with its ever-growing demands, leaves little time for the pleasures of gardening. But sometimes gardening itself is the culprit: elaborate, traditional perennial borders; water-hungry or disease-prone plants; needy lawns; and high-maintenance plants that require staking or clipping all suck up precious hours. Simply put, we need to start gardening in a whole new way. In this inspiring book, Val Easton shows exactly how to have a low-maintenance garden that doesn't sacrifice style. You won't have to give up your favorite plants or settle for expanses of ugly bark nuggets. You just have to unlearn some bad old habits and pick up some good new ones. So, how do you go about making a "new" low-maintenance garden? First, design your garden with maintenance in mind -- good-looking hardscape will both save weeding time and showcase your favorite plants. Second, simplify your garden routines -- learn the most efficient planting and maintenance techniques and don't get stressed if everything isn't letter-perfect. Third, learn how to work with nature rather than against it. And finally, embrace home-grown fruits, herbs, and vegetables; well planted containers; and thoughtfully chosen plants. The New Low-Maintenance Garden doesn't just tell you how to garden in a whole new way -- it shows you, through profiles and beautiful photographs of real gardens that embody low-maintenance techniques. The pressures of life are not likely to ease up anytime soon, but the lessons of this timely book will help you replace guilt over undone garden choreswith pleasure in your garden successes.

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