Troubleshooting Preventative Maintenance

1. Troubleshooting Preventative Maintenance MAIN 220 Fall 2003 Updated Spring 2008

2. Preventative Maintenance • Objectives • 6 steps Preventative Maintenance • 8 types of Preventative Maintenance understand them and choose best one for troubleshooting • reading assignments and schedule calendar for processes types of troubleshooting Chapter 19 How To Establish a 6 step PM program Rockis textbook chapter 18

3. 6 PM Steps • Select the Areas • Define • Establish Frequency of Assignments • Prepare the PM Assignments • Schedule PM Assignments Annually • Expand the Program FOR MORE INFO... MMSM Chapter 19

4. How to Apply 6 Steps • Select a Critical Unit • Define PM Requirements • Establish PM Frequency • Prepare PM Assignments • Schedule PM Assignments • Expand the System

5. Ask yourself • What is the difference between Preventative Maintenance and Predictive Maintenance • What is the difference between a Work Ticket and a Preventative Maintenance Ticket?

6. Predicative Maintenance • Most companies base their predictive maintenance programs on vibration analysis or interval timed, visual inspection. and that is why we find "reactive maintenance" the norm in most plants. How many times have we heard the expression "I did not have time to do the job correctly (realignment, dynamic balancing, etc.) because I had to get the pump back on stream". • A more sensible approach to predictive maintenance is to monitor the equipment for changes that could be destructive in the future, but allow you to correct them before the destruction starts. I spent my formative years in nuclear power. If, as an operator, you did something wrong that would be harmful to the atomic reactor it would "scram" and shut down immediately. But if you took an action that could be potentially dangerous, the reactor would start an "insertion" that would start to slowly shut down the reactor and give you time to correct what ever it was you did.

7. Correct parts materials Machine set up for that application Loose belts Leaks in air, steam, water, power Dripping Lubricant Electric Arcing Changes in sound of machinery Common Issues

8. Work Ticket • Used to identify the problem for the troubleshooter • When • What • When • Where • Quality System to measure output

9. RCM • The idea is to prevent damage • PM sheets differ than Work Tickets • Tell when and what was prevented

10. Reliability Centered Maintenance • RCM is "to determine the maintenance requirements of any physical assets (EQUIPMENT) in its operating context.“ • This is accomplished by answering questions about the equipment in order to determine what type of maintenance strategy to employ for the asset. RCM provides a flow diagram that tells you what type of maintenance to use based on the answers to the questions.

11. Root Cause Maintenance • RCA is "to uncover the underlying reasons (root causes) why an event (not just equipment but any type of event) is occurring so that the necessary steps can be taken to eliminate the event in its entirety." • This is accomplished by analyzing the modes (the point at which RCM stops). RCA uses a logic tree that stresses verification at every level. The advantage is that the actual root causes that are uncovered are facts that have been derived from the verification process.