What are the steps for appling the preventive maintenance in any plant ?

Preventive maintenance is performed according to the service booklet provided by the equipment agent or provider which is authered by manufacturers expertise

to applay the preventive maintenance plan you have to do the following:-

1- you have to study the production line and plant area  invironment and the machines theorys

2- devided the machines to many branches like gear boxes, bearing, haydrolic, pnumatic and etc...

3- start to establishing the lubrication plan for all parts.

4- start to establishing the daily , weekly, monthly and etc. maintenance tasks plans for maintenance team and production teams for each machine

5- start to establishing the daily check list ( its a very important )

6- start to implement the system and collect the result to make the fine tuning of this scaduals acording to the feed back from the down time report .

all of this steps depending on recomendations of the machines fabrecators and your experiance.

preventive maintenance can be perfectly managed through two directions:

1- Each machine mamufacturer's technical catalogue ( action, duration, types of spares, spec... etc)

2- Due to the different condition ( weather, spare parts materials and quality) than manufacturer there is deep need to modify the last recorded data( original period for maintenance and the type of lubricants specially)  due to the higher temprature in Egypt the viscosity of the oil going lower and thus it needs to be changed with new lubricant with same application but with higher viscosity and this for example.

If you need to apply a preventive maintenance system in your plant you have to do the following:

1-    The first you have to make survey for all location available in your plant and prepare the list of equipment and tolls related to each section (Mechanical,  Electrical, …)

2-    Then you have to study the production line & environment plant

3-    Prepare the preventive maintenance instruction for each asset in the plant from the fabricators catalog or from your old experience

4-    Assign your labors with time needed to each preventive maintenance work

5-    Prepare master plan (One Year) for all sections in the plant including in it the daily. Weekly, Monthly, Quarterly, Half yearly, and Yearly PM Work orders.

6-    All previous details should be filled in CMMS program to automatically generate your PM Work orders.

7-    You are ready now to cover all PM in the plant.

It all depends on the complexity of the plant and the level of maintenance, but can be generalized as:

1. Assess the plant and machinery for its operational aspect, can be done through visual, manufacture detailings etc
2. Understand the production process, product line, conversion process, 
3. Evaluate the sequence of the production to identify critical components
4. Categories it to mechanical, electrical, electronic components/machinery and list them out
5. Then check previous records for breakdown etc/ preventive cycle from the manufacturer
6. Inspection of the plant prior to documentation and procurement
7. Then check the environmental impact, and HSE aspect
8. Identify special requirements for work like fall protection, glows, heat resistant suit, special tools etc
9. Last maintenance records, spare utilization records, material utilization records (if any)
10. Then detail out the preventive maintenance plan for particular duration (hours, day, week, months, years etc)
11. Part change/repair list to detail the parts that is to be changed or repaired
12. Evaluate the available tools and determine if tools are to be procured
13. Evaluate and determine the inventory or spares if required request for procurement
14. Duration of maintenance for each section
15. Detail out the maintenance utilization material (parts, components, lubrication, oils, grease)
16. Work out the plant shut down procedure, start-up procedure and task assign matrix and initiate plant shut down activity
17. Finally perform the preventive maintenance and record the time, material, no of labour, time and parts etc
18. Identify if any work is needed to be checked on later (can be avoided most cases if inspection is carried out before plant shut down). At times it so happens certain defects can be identified during the maintenance
19. Associate the defects to minor, major and critical and workout the critical defects as fast as possible and rest depends on the time and availability of materials
20. Perform final technical inspection 
21. Initiate plant start-up procedure
22. Maintain plant shut down, maintenance, start-up details which can include the cost involved 

Well this is so elobrate as i mentioned some management and technical aspects. 

To organize a PPM schedule, the first step is to study the characteristic of the system, system life cycle and system component characteristic & life cycle. Trouble shooting and fault diagnosis ability is also a major criteria to improve and perfect the PPM schedule.

• Study Machine manufacturer recomondation and keep checklist ready.
• Categories machine mainly in two parts moving parts / non moving parts. Moving parts need more attension.
• Cleanliness is also very importanat factor in preventive maintenance.
• Catergorise machine Electrical Mechanical/Pnumatics/ HydraulicsPreventive Maintenance / Mechanical
• Electrical Prevt. maintenance mainly do ot leave loose connections.
• Pnumatics / Hydraulics should be leake proof.
• Mechanical tighened all nut and bolts.
• Complete checklist. Ensure nothing has left. Test the machine or equipment for readyness for production.
• If required checklist can be modified baseed on historycard to avoid diff probelm faced by us.
• Most improtant is spare required for next time should be recorded.& keep ready. 

Preventive Maintenance, to prevent downtime, which is allways costly in the driven enviroment we live, time is money.

machinery operating24/7365 days a year, would need service and maintenace time allocated, but to prevent breakdowns and downtime, we need to perform preventive maintenance duties.

this must be outlined in a check list for daily weekly and monthly.

the staff operating the machine working closely with the technical department should have a organised system in place, this is a requirment as important as delivering the product the machine produces.

equipment and machinery are a very expensive outlay for any company initially, the cost of productity is dependent on the machine working as its designed to, and to maintain it to allways be as productive, if this is not done then the purchace/installation costs would not be recovered. thus not generating a profit, as breakdowns will consume a large buget. not to mention poor quality.

staff on the floor, fellow subordinates and senior management need to take this concept and adopt a team attitude, which includes all of the above, there sould also be systems to be held accountable for the area and level you work in and responsiblity taken to maintain each part,

many technical staff only rely on what the staff have reported to repair as they dont work on the machine they dont know whats going on.

good housekeeping is important, getting the equipment kept clean at all times, allows for staff to identify issues that seem to lurk in the background, not visable to the eye until a breakdown occures.

having suitable qualified is key and ongoing traing not only to quailfied by all staff in the work area, have a learning enviroment. with good comunication at all levels, and a open door policy.

the actual maintaince reporting should be done online, with planned unplanned total preventive maintenance, catargories. the staff at all levels have access to this and disaplinary measures for not completing job cards loaded, or daily, weekly and monthly tasks.

the more urgent issues must be emailed and cc' to all involved on machinery, and technical and management. this is a team effort, and one weak link in the team can cause a link to break causing a chain of events that may be undesirable for any company.

Thank-you