The company recruit you to elaborate a preventive plan, how do you proceed?

Preventive Maintenance can be only be meaningful  if there is system in place, by Plan Outage which result the equipments to work efficiency.

Preventive maintenance can only best be meaningful if there is a system in place, i mean structured maintenance plan using software like Coswin hand in hand with Webrep.....if you want details of how it works contact me on my mail.

We can also implememt things like walk about..etc.etc

Preparation of PM Schedule:

# Collect preventive maintenance manuals and recommendations including drawings and plant layout for all the machines, facilities and utilities in or for the process/production line.

# Listing of all machinery as according to process flow.

# Understand production/rpocess demands/requirements to produce.

# List of all PM timing or interval to carry out the service maintenance and make adjustment against production tight schedule.

Preventive maintenance (PM) will be more effective with the support of other requirement such as experience and knowledgeable technicians, adequate spare parts, drawings, communications tools, good suppliers or vendors, repair tools, management +ve support, proper planning and coordination with production stoppage time (short stoppage window, year-end stoppage, product changes, etc.), budgeted maintenance cost, storage & retrieval system, parts labelling, etc.

Other then PM, the Maintenance Department shall also establish monitoring requirement, the wear & tear of parts trends or part failure trend in order to carry out or planned corrective maintenance activities to avoid machines fails during production peak requirements and to avoid costly breakdown. Maintenance Department too shall be able to identify what other working tools are required and prepared accordingly before actual maintenace to be carried out.

For good and effective PM, it is advisable to ensure the availability of drawings (other then machinery) for such as distirbution of electrical supply (DBs, MCCBs, MCBs panels), machines M&E drawings, water supply, pneumatic, proper labelling of electrical wirings in the DBs/MCCBs/MCBs and machinery, LPG system, fire fighting system, etc.

Standardize of parts or components(where is applicable) based on experience is greatly in helping to reduce time loss in maintenance. Availability of modern technology shall assist to troubleshoot, repair and storing of  material & retrieval of information. 

Below are just some example of action plan and not limited;

Documentation storages & retrieval:

# Establish a place including racking and shelf for keeping all relevant operating and maintenance manuals, drawings (Civil, M&E, penumatics, etc.).

# Establish control system (cataloging, storage, retrieval).

Spareparts storage & Retrieval:

# Ensure a proper place for spare parts storage and control (category, tracking, monitoring).

# Store shall be located and easily visible to security monitoring.

# Installed CCTV (if necessary).

# Establish monthly, quarterly & yearly internal physical stock check VS record declared.

As an inputs for the process of elaborating a preventive maintenace plan, I note:

* Machines's operational manuals (Technical documenst)

* Eventual related preventive maintenance recording

* Some feedback from the machines's operators

I ask all documents machines then I read to understand the maintenance procedure for each machine to go out with a maintenance plan daily, weekly, monthly, anual .... for each machine and that it is taking consideration instructions machine manufacturer.