A First time take on the Preventive Maintenance Process

Hello All

Here is a first take on comng up with a Process of Preventive MAintenance. While the industry may be extant with method to do this, here is a grass roots level understanding of the process. I would like to hear critical comments on this from the experts.

Preventive Maintenance Process

1.        Grade all parts/subsystems based on the following 3 criteria

a.        Cost (High(>  INR25000), Medium(Between INR 25000 and 15000), Low (Less than 15000)

b.        Probability of Failure in a given period (basedon the lifetime/reliability details of the part/sub system (High(> 70%), Medium (< 70% but .> 40%), Low (< 40%)

c.        Down time for repair, rework, replacement ( High(> 3 days), Medium (Between 1 day to 3 days), Low (Less than a day)

2.        Information to populate this table should be from existing data on part failures, life time studies, reliability data, down time records etc. This may be the most important and most time consuming step in this process and requires right staff and access to the correct information.

A table with fictitious parts/subsystems for elucidating

Part/Subsystem	Cost	Probability of failure					Down time for Repair/Replacement	Weighted Value- 3 months	Weighted Value- 6 months	Weighted Value- 9 months	Weighted Value- 12 months
		In  first 3 months	In first 6 months	In first 9 months		In first 12 months
A	H	L	L	M	H		H	HLH	HLH	HMH	HHH
B	M	L	M	H	H		M	MLM	MMM	MHM	MHM
C	L	M	M	H	H		M	LMM	LMM	LHM	LHM
D	L	M	H	H	H		L	LML	LHL	LHL	LHL
E	L	L	L	L	M		L	LLL	LLL	LLL	LML

3.        Determine acceptable weighted Average: If there is at least 1 H or M in weighted value, that part/ subsystem shall be considered under the preventive maintenance for that particular period (Example: Part E will be considered only during the preventive maintenance during 12^th month after installation since the Weighted Value has at least one M

4.        For each Preventive Maintenance session, list out the parts/sub systems that will be checked as per above table

5.        Define what constitutes “Part/subsystem is working as expected” and what constitutes “Part/subsystem not working as required”, performance creep etc.

6.        Define tests on how the part/subsystem will be checked for it fitness

7.        Define what test result would require the part to be replaced, repaired etc.

8.        Identify  measuring/monitoring subsystems requiring their calibration to be checked

9.        Define what constitutes acceptable calibration and out of calibration

10.     Define tests to check calibration status

11.     Define method to recalibrate, reverify

12.     Identify any moving subsystems that may require lubrication

13.     Identify parts requiring any specific cleaning routines

14.     Establish a Preventive maintenance plan for each device family for each subsequent preventive maintenance session (not all parts need to be checked at every session)

15.     For every installed device, establish a preventive maintenance schedule.

16.   For every PM schedule construct a proper format to capture all information without ambiguity.

17.  Train service people on what to look for during every PM visit