1. Presentation on Preventive Maintenance

2. Introduction Maintenance : Two basic categories :
All activities that maintain facilities and equipment in good
working order so that a system can perform as intended
Two basic categories :
Building and grounds
Equipment maintenance

3. Types of Maintenance Regular Maintenance Breakdown Maintenance
Generally maintenance can be done in the
following four ways :
Regular Maintenance
Breakdown Maintenance
Preventive Maintenance
Total Productive Maintenance

4. Preventive Maintenance :
Preventive Maintenance is the care and understanding of your assets basic needs, while in routine service.
Preventive Maintenance can also be described as the scheduling tool or action plan for managing the anticipated life expectation of “any” asset.

5. Objectives
To obtain maximum availability of the plant by avoiding breakdowns and by reducing the shutdown periods to a maximum.
To keep the machine in proper condition so as to maintain quality of the product.
By minimizing the wear and tear, preserve value of the plant.
To ensure for the safety of the workers.
To keep the plant at maximum production efficiency.
To achieve all the above objectives with most economical combinations.

6. Elements of Preventive Maintenance
Inspections or Check ups
Lubrication
Planning and Analysis
Training to maintenance staff
Storage of spare parts
Records and Analysis

7. The following records are generally maintained for “ Record and Analysis “ purpose :
Operation manual
Maintenance instruction manual
History cards and history registers
Spares procurement registers
Inspection register
Log books

8. Reasons for the need of a PM system
Increased Automation.
Business loss due to production delays .
Production of a higher quality product .
Just-in-time manufacturing.
Need for a more organized, planned environment.

9. Potential errors or damage of a P.M
Damage to an adjacent equipment during a PM task.
Reintroducing infant mortality by installing new parts or materials.
Damage due to an error in reinstalling equipment into its original location.

10. When Does Preventive Maintenance Make Sense
This is a logical choice that considers two conditions
#1. The component in question has an increasing failure rate.
#2. The overall cost of the preventive maintenance action must be “ less than the overall cost “ of a corrective action.
If both of these conditions are met PM would make sense

11. The key for a successful PM system
Scheduling – Should be automated to the maximum extent possible
Execution – Should be done before the actual break down occurs.

12. Motivating Preventive Maintenance Workers
Training programs – most effective
Establish inspection and preventive maintenance as a recognized, important part of the overall maintenance program.
Assign competent, responsible people to the preventive maintenance program.

13. Continued -
Follow-up to assure quality performance and to show everyone that management does care.
Provide training in precision maintenance practices and training in the right techniques and procedures for preventive maintenance on specific equipment.
Set high standards.
Publicize reduced costs with improved up-time and revenues, which are the result of effective preventive maintenance

14. Advantages These advantages are efficiently planned and well
executed preventive maintenance program :
Reduction in production downtime.
Lesser overtime pay for maintenance personnel.
Lesser number of standby equipments are needed.
Less expenditure on repairs.
Due to planned spare parts replacement, lesser spare parts are needed to remain in store at all times.
Greater safety to employees because of reduced breakdowns.

15. Summary PM is not difficult to achieve.
It is an essential part for cost reduction
There is an element of risk involved in PM
Careful planning and execution will reduce the risk of PM
The biggest benefits of a PM program occur through painting, lubrication, cleaning and adjusting, and minor component replacement to extend the life of equipment and facilities.

16. Total Maintenance Cost
Breakdown and repair cost
Optimum Amount of
preventive maintenance
Cost
Total Cost
Preventive maintenance cost

17. Thank U