Predictive and preventive maintenance is an approach that aims to optimise the economics of a piece of equipment by predicting when maintenance is required. It allows maintenance to be provided at the optimum trade-off point between service cost, extending equipment life and maximising throughput. We help our clients install predictive and preventive maintenance principles to prevent the expensive repairs and loss in revenue associated with equipment failure.
The essentials to our approach to predictive and preventive maintenance installation are comprised of the following five factors:
- Equipment Strategy. Most companies have too many pieces of equipment to be able to address them all the same way. We recommend putting an equipment strategy in place, to rigorously prioritise opportunities, ensuring focus is put on the highest impact items first. This approach creates stability and momentum among staff as they are able to focus on a manageable number of strategies rather than an apparently infinite number for all equipment.
- Prediction. In order to prevent damage and failure in equipment we need to be able to predict it. This is done through inspection and condition monitoring of operational parameters such as vibration or temperature for unexpected changes. In our experience, the most useful tools for monitoring equipment is often your crew’s and supervisor’s own senses. If used correctly (and safely!) your people’s eyes and ears can detect problems with equipment long before failure occurs.
- Assessment of response. We have seen considerable time and money spent treating failure symptoms while maintenance costs creep up. To prevent repeatedly treating failure symptoms, we ensure the maintenance team is conducting root cause analysis of identified abnormalities. If basic monitoring, scheduling and planning are not in place, root cause analysis will point to these deficiencies.
- Response. It’s crucial that you have well-communicated roles and responsibilities for the preventive maintenance team and other personnel that are involved in the process. Communicating and clarifying specific roles for every function of the process ensures that all actions are implemented – a pre-requisite for true predictive maintenance.
- Hard-wiring. The wiring phase ensures that the predictive maintenance process, roles and responsibilities are well managed and sustained. This phase is about effective, continuous implementation of the practices by the organisation. We help our clients establish a system to track performance and establish regular and formal reviews at all levels of the maintenance department. We create a closed loop system where supervisors perform effective short interval controls to ensure, for example, that actions don’t slip into the next day.