How to build an electrical maintenance program?

1- Ensure all strategy documents are captured in the CMMS and scheduled to occur during planned downtime.
The development of strategies, including entering them into a CMMS, is a very time-consuming process.
Resources must be made available for this to be done in a timely manner.
Not implementing strategy improvements in a timely manner will be viewed as a negative by your customer (production, management, etc.).

2- Start on the BOM process.
For planned work to run smoothly, materials must be listed against the equipment hierarchy so they can be easily identified and ordered.
Critical equipment may need to be kept in stock dependent on lead time and the consequence of not having the spare.
With electrical equipment, there has always been the dilemma of equipment being made redundant within very short timeframes, and this is often used as a reason to not start.
BOMing should be part of an overall strategy review process.
If new equipment is being installed, demand a parts list from the engineering team running the install before the project is completed.
Ideally, the cataloguing and BOMing of equipment should be part of the overall project.

3- Manage your electrical schematics and documentation.
How often has a machine not been repaired in an adequate timeframe because of the inaccuracies in schematics? Do you have schematics hand-drawn like the one below? Accurate schematics are a critical part of your electrical maintenance program.
A schematic accuracy review should begin based on your plant criticality assessment.
(The most critical assets first.) The best place to start is to gather all paper copies of schematics for a single piece of equipment and have your most experienced electrical personnel check what is correct.
From this, develop one marked-up copy of the schematic and have it stored electronically as either a CAD or picture file (.jpg,.
tif, .pgn, etc.).
You now have one updated schematic that can be accessed easily.
For most businesses, this will be a huge body of work initially, but the payoff is worth it.
And once your system is in order, it is much easier to manage.
Ultimately, the process of modification of schematics needs to be proceduralized and controlled.

4- Train your electrical personnel.
Develop a training matrix for your electricians.
The matrix should include an overview of specific and generic technologies and skills required of your people.
An example of a specific skill would be: Access and monitor Allen-Bradley PLCs.
A generic skill would be: Servicing of DC motors.
You could also include the need for understanding of production processes or just being familiar with a specific area of plant.

5- Ensure you have a documented process to effectively manage the workload.
Most electrical maintenance departments, whether they are one man or dozens, have to prioritize their work.
Prioritization should not be based on “who shouts the loudest” and should be based on importance and urgency.
Importance equals the value to the business, where urgency equals time limitations being applied to a task.
Ricky Smith, co-author of “Lean Maintenance” and “Rules of Thumb for Maintenance Practices” says: “The best companies have developed a proactive workflow model that is understood and is followed by all levels in the organisation.” The “workflow” model Ricky refers to needs to include a process for managing breakdowns, a process for planning, a process for scheduling planned tasks, a process for managing work that will break a fixed schedule, and a method for capturing improvements that can be fed into the system.

  First of all, you have to know the types of Maintenance Process.
There are two types of maintenance process a) Corrective Maintenance: It is an instant troubleshooting process.
This event can occur frequently.
b) Preventive Maintenance: This type of maintenance is performed regular basis to prevent sudden breakdown of machineries and also reduce the corrective maintenance.
Between these two processes corrective maintenance is vital because it is directly related to production process.
However first I will discuss about corrective maintenance then preventive maintenance.
a)    Corrective Maintenance: 01.Classify the total machine according to the importance of production line.
You can arrange a meeting with production department for this issue.
They will help you to find which machines are more important.
02.Classify the total manpower according to their specialization and skill.
Arrange a meeting with your own manpower and discuss about this matter.
It will help you to classify them according to their specialization and skill.
   03.Engage the more skilled people for the most important machine of production line.
04.Engage the less skilled people for the less important machine of production line.
05.Find out a little time form every week for train up the less skilled manpower.
If you can continue this process, smooth production can be achieved easily.
06.Keep records of every corrective maintenance process.
You may keep type of fault, cause of fault, remedy for fault etc as record.
This data will help you to troubleshoot in future.
    It is a generalized step by step process for corrective maintenance.
You can re arrange it according to your own organization’s type b)    Preventive Maintenance: 01.Classify the total machine according to the importance of production line and find out idle time of the each machine.
You can arrange a meeting with production department for this issue.
They will help you to find which machines are more important.
02.Make a schedule for preventive maintenance for2-3 month.
Make the schedule such a way that each machine gets preventive maintenance once per2-3 month.
03.During preventive maintenance check all the cable connection/joint, remove dust from electronic component (PLC, DC or AC drive, sensor etc) and also check the cable condition.
If you notice any abnormal contrition then repair it.
04.Check the machine safety and finally when you feel this machine is safe and at sound condition then handover it for continuous production.
Mainly it is a process for reducing running fault.
If you can continue this process properly, the running fault will reduced.
  This two process that I discuss is my opinion not traditional rule.
I will be happy if it does any good result for you.
Let me know if you have any confusion.
Thanks                      

1-Acknowledge your current situation.
2-Develop a vision for your electrical maintenance program.
3-An electrical planner will be employed within the next three months.
All critical equipment will have maintenance strategies developed within 12 months.
Strategies for less-critical equipment will be developed within 24 months.
A system for the upgrade and management of electrical drawings will be developed and implemented in the next 12 months.
All strategies will maximize the use of condition-based maintenance.
Tradesmen and other relevant personnel will be trained so they can effectively apply strategies.
Implement down days for electrical equipment.
4-Get the support from the electrical work group.
Discuss your plans for the future with your work group.
5-Gain support from your management.
If management is not willing to support your vision, then there is little chance of success.
Document your vision, highlighting the benefits and prospective gains, and your ideas! Be prepared for some hard questions and be confident to back your judgment.
6-Resources will be required to effectively implement changes.
7-Gather history of failures.
8-Understand other potential causes of failure.
9-Understand the criticality of your electrical assets.
10-Develop preventive maintenance inspections and task lists that minimize known and hypothetical failure modes.

--You must read and understand the equipments services & maintenance manual

 write down the required previntive and corrective maintenance for each machine and  the maintenance period

make simple design for the maintenance sheet to distributted for you technechains

thank you