Department of Defense Voluntary Protection Programs Center of Excellence Development, Validation, Implementation and Enhancement for a Voluntary Protection Programs Center of Excellence (VPP CX) Capability for the Department of Defense Department of Defense Voluntary Protection Programs Center of Excellence Preventive Maintenance Development, Validation, Implementation and Enhancement for a Voluntary Protection Programs Center of Excellence (VPP CX) Capability for the Department of Defense

Objectives After this training you will be able to: –Define a Preventive Maintenance (PM) system –Recognize reasons and need for a PM system –Define advantages of a PM system –Recognize risks of a PM system –State the law of PM –Describe the PM execution process –Describe ways to fix data absence –Define ways to motivate PM workers.

What is Preventive Maintenance? Preventive maintenance is a schedule of planned maintenance actions aimed at the prevention of breakdowns and failures. The primary goal of preventive maintenance is to prevent the failure of equipment before it actually occurs. Designed to: –Preserve and enhance equipment reliability by replacing worn components –Ensure machine failures are not the cause for workplace mishaps.

VPP Requirements for Preventive Maintenance A written preventive and predictive maintenance system must be in place –VPP Federal Register Notice 65: , 7/24/2000 Equipment must be replaced or repaired on a schedule, following manufacturers’ recommendations Documented records of maintenance and repairs must be kept The system must include maintenance of hazard controls such as machine guards, exhaust ventilation, mufflers, control circuits and devices, etc.

Need for PM System A PM system aligns with a safety management program to: –Prevent injuries caused by malfunctioning equipment –Increase automation – Reduce losses due to production delays – Improve quality –Just-in- time manufacturing – Provides a more organized work environment.

Advantages of a PM System Some advantages of a PM system include: –Reduced production downtime –Conservation of assets and increased life expectancy of assets (both machine and human) –Ensuring all equipment safety features are functioning properly –Reduced cost of repairs by reducing secondary failures –Quality products –Identification of equipment with excessive maintenance costs –Improved safety and quality conditions.

Errors of a PM System PM system errors could include: –Damage to an adjacent equipment during a PM task –Damage due to an error in reinstalling equipment into its original location –Damage due to the installation of new parts.

The Laws of PM Programs The higher the value of plant assets and equipment per square foot of facility, the greater will be the return.

Things to Consider Things to consider after completing a maintenance operations: –Ensure equipment meets manufacturer’s specification –Review job hazard analysis (JHA) to ensure equipment alterations or equipment maintenance did not introduce new hazards not included on the JHA –Conduct machine checks to ensure all feature, especially safety devices, are functioning properly –Ensure employees are aware of any changes to equipment and/or operating procedures.

A Successful PM System Three keys for a successful PM system: –Scheduling: Should be automated to the maximum extent possible –Execution: Should be done before an actual break down occurs –Quality: Should have a formal process for checking the quality of repairs.

PM Focus PM focus should be on: –Cleaning –Lubrication and inspection –Correcting deficiencies –Operation of safety devices Pre-determined parts replacement should be minimal and done only where evidence clearly indicates wear-out characteristics.

Data Absence When data on PM is absence some techniques which can be used to assist in its creation are: –Structural/facility –Age exploration programs –Statistical analysis –Safety inspection data Cost should not be a primary factor in deciding against data collection for a PM system.

Preventive Maintenance Workers Ways to motivate your PM workers include: –Establishing effective training programs –Establishing inspection and preventive maintenance as a recognized, important part of the overall maintenance program, including follow-ups –Assigning competent, responsible people to the preventive maintenance program –Setting high standards –Publicizing reduced costs with improved up-time and revenues and employee safety, which are the result of an effective preventive maintenance system.

Summary In this presentation you learned about: –PM –Reasons for the PM system –Advantages of a PM system –Errors of a PM system –PM after action items –Successful PM system –PM focus –Ways to motivate PM workers.