The Power of Prevention: What You Should Know About Planned Preventive Equipment Maintenance
The goal? To notice small problems and fix them before major ones develop. A strong PPEM plan is the key to keeping your equipment in safe working condition, reducing unnecessary maintenance costs due to unplanned failures and increasing your team’s productivity overall.
An effective PPEM program requires careful planning and scheduling of maintenance before an actual breakdown occurs. It’s crucial to remember that effectiveness most optimally occurs when 80% (or more) of your maintenance activities can be planned and scheduled at least one week in advance.
The steps below are some of the most important needed when any PPEM can be implemented.
Determine Your Goals
Who will be involved in the project? Staff members must be fully invested in the development of the program to assure its success. You’ll want to also determine your goals for the project prior to beginning. For example: decrease equipment downtime by X percent.
Maintain an Accurate and Detailed Inventory List
Next, take inventory of your facility equipment and assets. It’s a time-consuming task but a critical one as it ensures that preventive checks are routinely made on key operational equipment. Take note of the important details, such as make/model, serial number, specs, asset ID numbers, and fixed locations. Document the current condition of the equipment to prioritize levels of importance as part of the preventive program.
Put Procedures in Place
Create preventive maintenance procedures by determining the tasks or jobs required to maintain each piece of equipment, as well as the frequency with which these tasks should occur (i.e. weekly, monthly, quarterly, semi-annually, annually). Most preventive maintenance programs are scheduled based on run-time hours, but knowing in advance how often these may occur will assist in your company’s scheduling process. In addition, make a list of tools and internal/external resources needed to complete each job. Include any safety procedures such as lockout-tagout and how long each procedure will take to complete.
Establish High Priority Maintenance Items
Create procedure schedules to help minimize workflow productivity disruptions. To do so, make a list of high priority maintenance items; these will be the starting points. Preventative maintenance programs take time to be created but by tackling high priority maintenance items first, you’ll focus on which pieces of equipment are most costly to your company regarding repairs, downtime, and value to operations. This will assure you do not overload staff.
Training is Key
And lastly, you want to train your team. Having staff members trained to use a program is a key determinant of successful outcomes. It is essential to prioritize the training of maintenance staff as they are the core users of the program.
Measure the Program’s Success
Once your program is up and running, how do you know if it’s working? Preventive maintenance programs should deliver positive outcomes. These outcomes include reduced unplanned downtime due to equipment failure ― which consequently helps prolong equipment life ― translating to less unnecessary maintenance or inspections, decreased injuries, and higher profits over time.
If you don't see these benefits, it’s time to start rechecking your program.
The information contained in this article is for informational, educational, and promotional purposes only and is based on information available as of the initial date of publication. It is the reader’s responsibility to ensure compliance with all applicable laws, rules, codes and regulations. If there is any question or doubt in regard to any element contained in this article, please consult a licensed professional. Under no circumstances will Global Industrial be liable for any loss or damage caused by your reliance on this article.