preventive maintenance
TRANSCRIPT
Preventive Maintenance
Preventative Maintenance
• What is a Preventive Maintenance?
– Preventive Maintenance is planned maintenance that is designed to improve Equipment life and avoid breakdowns on the plant.
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Preventive Maintenance: Basics
Basics
Task list
Single cycle plan
Strategy plan
Maintenance plan scheduling
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Time-based Performance-based Condition-based
Preventivemaintenance
Temperature
Thickness
PressurePressure
10102020
3030 4040 50506060
70708080
Pressure
2000
Types of Preventive Maintenance
Preventive Maintenance
• An Equipment can require maintenance activities to be performed based upon either time or a certain condition being met.
External visual inspection
1 month4Wks
Internal visual inspection
12 Wks
Check gear teeth for wear
52wks
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Preventive Maintenance: Phases and Roles
Maintenancetechnician
Maintenanceorder
Process maintenance orders4
Maintenanceplanner
Maintenanceplanner
Maintenancesupervisor
MaintenanceplannerTask list
Maintenanceplan
Schedule
Technicalcompletion
Create maintenance plans
Schedule maintenance plans
Technically completemaintenance orders5
2
3
1 Create task lists for differentobjects
Phase Contents Roles
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Preventive Maintenance: Task List
Basics
Task list
Single cycle plan
Strategy plan
Maintenance plan scheduling
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What?
Why?
For preventive maintenance (maintenance and inspection)
For routine maintenance (planned repairs)
For preventive maintenance (maintenance and inspection)
For routine maintenance (planned repairs)
Operations
Maintenance work centers
Material components
Production resources/tools
Maintenance packages
Task List
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Task list header
Operation 10Operation 20Operation 30
Planner group
Maintenancestrategy
3 months
3 months6 months
6 months12 months
12 months
Work center
Production resources/tools
Components
Maintenance Task Lists: Structure
Maintenance Strategy
• What is a Maintenance strategy?
– A Maintenance Strategy defines the frequency and scheduling data for Planned Maintenance activities.
Maintenance Strategy
4 Week 12 Weeks 24 Weeks
Time
Strategy
Package definition
2000
Scheduling parameters
What is a Maintenance Package?
Maintenance Package
3 months12
Weeks
Package number
Description
Cycle length
Unit of measurement
HierarchyOffset
•Maintenance packages define the frequency at which specific operations are executed. You can assign maintenance packages to the operations in a task list.
•Maintenance packages are part of a maintenance strategy.
12 Wks12 Wks
24 Wks
12 Wks
Strategy
12 wks12 wks
24 Wks
12 wks
Strategy
Same hierarchy levels
Different hierarchy levels
12 Wks
24 Wks
10
10
12 Wks
24 Wks
20
10 X
Maintenance Package Hierarchy
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Basics
Task list
Single cycle plan
Strategy plan
Maintenance plan scheduling
Preventive Maintenance: Single Cycle Plan
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I must perform thesame inspections atregular intervals.
1999
1997
Inspection of"Portable fire extinguishers"
every 2 years
94 96
98
2000
CHECKED
Single Cycle Plan: Business Process
Single Cycle Plan
• Simple and quick way to create a preventive or inspection plan.
• Includes only one cycle or frequency.
• Can be either time or performance based.
• All operations on the Task list will be performed.
• More than one Maintenance item can be included.
What is a Maintenance Item -- ?
Maintenance Item• Every Maintenance plan will have at least one Maintenance
item.• A Maintenance item can only belong to one maintenance plan.• The Maintenance item contains the following information:
– Description (Becomes the Maintenance order description)– Technical object– Task list– Planning Data
• Order or notification type• Planner group• Priority• Main work center• Maintenance activity type
– Object list
Maintenance Item (Cont.)
• A Maintenance item can contain more than one Technical object.
• The Technical object can be an Equipment, Functional location or Assembly.
• The Maintenance item description becomes the description of the Maintenance notification or order.
• For Maintenance items that are part of a Strategy based plan a Maintenance strategy must be included within the item.
• The Task list for this Maintenance item will also need to be linked to the same Maintenance strategy.
Single Cycle Plan Steps
• Three steps in creating a single cycle plan.
Task List
Task List GroupPRTsComponents
Maintenance Item
Technical ObjectTask ListPlanning Data Maintenance Plan
Maintenance ItemScheduling Param.Cycle (Frequency)
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Scheduling Data and Maintenance Item
Responsibilities/Planning data
Referenceobject
Task list(optional)
3 months
Interval (cycle)
Maintenance item
Maintenance plan
Scheduling data
Maintenance item
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Using a Task List to Include an Operation List
Maintenance plan
Scheduling data
Maintenance item0010 Switch off
0020 Safety check
0030 External visual check
0040 Change seal
0050 Exchange H9 casing
0060 Check Z7 wire
Task list
Single Cycle Scheduling
Cycle Start
15.06.2004
15.03.2004
Cycle12 Weeks
Maintenance plan
Scheduling data
Maintenance item
Planned Date
15.09.2004
1
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Preventive Maintenance: Strategy Plan
Basics
Task list
Single cycle plan
Strategy plan
Maintenance plan scheduling
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Which parts must bemaintained at whichintervals?
External visual inspection
1 month1 month
Internal visual inspection
3 months3 months
Check gear teeth for wear
1 year1 year
Strategy Plan: Business Process
Maintenance Plan Steps
Task List
Task List GroupMaint. PackagesMaint. Strategy
Maintenance Item
Maint. StrategyTechnical ObjectTask List
Maintenance Plan
Maint. StrategyMaintenance ItemScheduling Param.
Strategy
Maintenance Packages
The Task List checks the Package to ensure the Strategy still exists.
The Item checks the Task List to make ensure that the same Strategy is used
The Plan checks the Item to make ensure that the same Strategy is used
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Task List and Maintenance Strategy
6 months6 months
3 months3 months
3 months3 months
6 months
3 months
Strategy
0010 Switch off
0020 Safety check
0030 External visual check
0040 Change seal
0050 Exchange H9 casing
0060 Check Z7 wire
Task list
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Creating a Time-Based Strategy Plan
3 months3 months
6 months
3 months
Strategy
0010 Switch off
0020 Safety check
0030 External visual check
0040 Change seal
0050 Exchange H9 casing
0060 Check Z7 wire
Task list
3 months3 months6 months
6 months
Maintenance plan
Scheduling data
Maintenance item
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Preventive Maintenance: Maintenance Plan Scheduling
Basics
Task list
Single cycle plan
Strategy plan
Maintenance plan scheduling
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ManualManualcallcall
NewNewstartstart
Start inStart incurrentcurrentcyclecycle
ScheduleSchedule
Last actual dateLast maintenancepackage
Last actual date
Nextplanned dateNext maintenancepackage
Cycle start
*
* Only for strategy plan
Schedule Maintenance Plans
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Cycle Start and Planned Date
Planned date
Order exactlyon planned date?
Cycle3 months
Cycle start
14.04. 2000
15.01.2000
Order 901760Maintenance plan
Scheduling data
Maintenance item
1
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Maintenance item report, sorted by equipment (no.)
1998 1999
Maintenance Scheduling Overview
... or as a listWith display variantsWith general list viewer
... as a graphicWith maintenance plan simulationWith/without details