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    Implementing Preventive Maintenance for Industries the Right Way: 1, #11
    Implementing Preventive Maintenance for Industries the Right Way: 1, #11
    Implementing Preventive Maintenance for Industries the Right Way: 1, #11
    Ebook620 pages7 hours

    Implementing Preventive Maintenance for Industries the Right Way: 1, #11

    By Rolly Angeles

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    About this ebook

    This book refers to Discipline Number 5 based on the original book I wrote in 2009 on World Class Maintenance – The 12 Disciplines. Almost all industries have their Preventive Maintenance, but still, many problems emerged and the question is can we do something about it.  Many maintenance people from industries are not satisfied with their current Preventive Maintenance even if they are complying with every single maintenance task listed.  My sole intention in writing this book is to provide a guide and direction to help maintenance in industries get the results in doing the correct Preventive Maintenance on their equipment and assets.  In today's digitalization era, and with all these advanced CMMS and EAM software, apps, technology, cloud, smart sensors, Industrial Internet of Things, and automation, the majority of industries are jumping on the bandwagon thinking that these technologies will optimize their asset.  I have nothing against technology, but what I am stating is that everything will boil down to one thing and that is addressing the basics first.  The goal and objective of having Preventive Maintenance are to prevent or anticipate a failure or breakdown from happening first.  The keyword in this case is being first.  This means that we need to perform an activity or task before failure happens.  But the thing is we need to be precise in what failures can be addressed by PM since not all failures can be prevented in the first place. This book refers to Discipline Number 5 based on the original book I wrote in 2009 on World Class Maintenance – The 12 Disciplines. Almost all industries have their Preventive Maintenance, but still, many problems emerged and the question is can we do something about it.  Many maintenance people from industries are not satisfied with their current Preventive Maintenance even if they are complying with every single maintenance task listed.  My sole intention in writing this book is to provide a guide and direction to help maintenance in industries get the results in doing the correct Preventive Maintenance on their equipment and assets.  In today's digitalization era, and with all these advanced CMMS and EAM software, apps, technology, cloud, smart sensors, Industrial Internet of Things, and automation, the majority of industries are jumping on the bandwagon thinking that these technologies will optimize their asset.  I have nothing against technology, but what I am stating is that everything will boil down to one thing and that is addressing the basics first.  The goal and objective of having Preventive Maintenance are to prevent or anticipate a failure or breakdown from happening first.  The keyword in this case is being first.  This means that we need to perform an activity or task before failure happens.  But the thing is we need to be precise in what failures can be addressed by PM since not all failures can be prevented in the first place.

    LanguageEnglish
    PublisherRolly Angeles
    Release dateApr 15, 2022
    ISBN9798201672140
    Implementing Preventive Maintenance for Industries the Right Way: 1, #11

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      Book preview

      Implementing Preventive Maintenance for Industries the Right Way - Rolly Angeles

      Original Concept of World Class Maintenance Management

      The 12 Disciplines (Series 1)

      1

      FIGURE A: ORIGINAL Concept of World Class Maintenance

      By: Rolly Angeles

      Table of Contents

      Original Concept of World Class Maintenance Management

      The 12 Disciplines (Series 1)

      Table of Contents

      Acknowledgment

      About the Author

      Take Quiz on Preventive Maintenance Part 1

      Take Quiz on Preventive Maintenance Part 2

      Preface: Those Were the Times

      Chapter 1: Changing The Way We Think About PM

      1.1: The Traditional Belief in Preventive Maintenance

      1.2: Top Ten Problems on Preventive Maintenance

      1.3: Mistaken Belief about Preventive Maintenance

      1.4: Why Preventive Maintenance is Costly in Majority of Industries

      1.5: Grave Concern about Government Laws on Outages

      1.6: Understanding When to Use Preventive Maintenance

      Chapter 2: Understanding the Concept of Preventive Maintenance

      2.1: The Objective of Maintenance

      2.2: Different Terminologies on Maintenance Tasks

      2.3: Different Maintenance Tasks Explained

      2.4: Preventive Maintenance Explained

      2.5: Understanding the Process of Wear

      2.6: Most Common Types of Mechanical Wear Explained

      2.7: The Maintenance Organization: Everyone is Connected

      2.8: Why Preventive Maintenance is Important

      2.9: Is Preventive Maintenance Feasible or Not?

      Chapter 3: Building a Solid PM Structure in the Plant

      3.1: Phase 1: Preparatory Activities for Preventive Maintenance

      3.2: Phase 2: PM Tasks Execution Includes

      3.3: Phase 3: PM Feedback and Evaluation

      Chapter 4: Planning and Scheduling for PM

      4.1: Needed Non-Productive, Not Needed Non-Productive, and Productive Work

      4.2: Concept of Planning and Scheduling for PM

      4.3: Who Is the Perfect Fit for the Maintenance Planner?

      4.4: Preventive Maintenance Bill of Materials (BOM)

      4.5: Reducing Breakdowns by Taking Care of the Basics

      4.6: What Tasks Should PM Include

      4.7: Why Most Planners Cannot Plan Future PM Work

      4.8: Do Not Expect the Plan to Always be Perfect

      4.9: Scheduling Work for Preventive Maintenance

      4.10: Providing a Before and After Photo After Restoration

      Chapter 5: Integrating Precision Maintenance in PM

      5.1: Human Errors in Maintenance

      5.2: Precision Maintenance Explained

      5.3: History of Precision Maintenance

      5.4: Knowledge and Skill of Maintenance

      5.5: Requirements for Precision Maintenance

      5.6: Other Applications of Precision Maintenance

      Chapter 6: PM Interval, Are We Doing PM Too Late or Too Soon?

      6.1: How Did Maintenance Arrive at the PM Interval?

      6.2: The JIC Concept

      6.3: Determining the Correct Interval for PM Overhauls and Replacement

      6.4: Determining the Correct Interval for PM Human Inspection

      6.5: Selecting the Maintenance Interval for Greasing Bearings

      6.6: Selecting the Maintenance Interval for Changing Oil

      6.7: Selecting the Maintenance Interval for Failure Finding Tasks

      6.8: Selecting the Maintenance Interval for Redundant Components

      6.9: Selecting the Maintenance Interval for Predictive Maintenance Tasks

      6.10: Decision to Perform Corrective Maintenance on PdM

      6.11: Refining the PM Interval

      Chapter 7: The Role of MRO Spare Parts on PM

      7.1: MRO Spare Parts for Preventive Maintenance

      7.2: The Lead Time to Order

      7.3: Storekeeper Access to PM Schedule

      7.4: Shortening the Travel Time to the Storeroom

      7.5: Do Not Believe Everything the OEM Tells You to Stock

      7.6: Factors to Consider in Stocking Parts or Not In the Storeroom

      7.7: MRO Decision Diagram on Whether to Stock or Not to Stock

      7.8: Case Samples on How to Use the MRO Algorithm and Form

      Chapter 8: Involving Operators in Maintenance

      8.1: Why Operators Should be Involved in Maintenance

      8.2: The Most Important Thing About Operator’s Involvement

      8.3: Standards to be Developed by Operators

      8.4: Consolidating Operators and Maintenance Activities

      8.5: Tips on How to Involve your Operators in Maintenance

      8.6: Detailed 7 Steps Implementation of Autonomous Maintenance

      Chapter 9: The Role of Predictive Maintenance on PM

      9.1: Predictive Maintenance Explained

      9.2: Potential and Functional Failures

      9.3: Difference between CBM and Predictive Maintenance

      9.4: Vibration Monitoring

      9.5: Infrared Thermography

      9.6: Ultrasonic Monitoring

      9.7: Oil Analysis Explained

      9.8: The Role of Predictive Maintenance on PM

      9.9: Combination of Tasks

      Chapter 10: Deriving the Maintenance Tasks

      10.1: The Reason RCM Was Developed by the Airline Industry

      10.2: Deriving the PM Tasks Through RCM

      10.3: Streamlined RCM Version

      10.4: Before Deriving the PM Tasks Consider the Operating Context

      10.5: Sources of Failure Modes

      10.6: What the PM Task Should Include

      10.7: Collaboration Between the People Involved in PM

      Chapter 11: Measuring PM Effectiveness and Performance

      11.1: Why We Need to Measure our Efforts on PM?

      11.2: Machine Breakdown and Frequency

      11.3: Preventive Maintenance Compliance

      11.4: Preventive Maintenance Effectiveness

      11.5: Maintenance Backlog

      11.6: Should We Measure Wrench Time on Maintenance?

      11.7: Percentage of Maintenance Cost to RAV

      11.8: Mean Time between Failures (MTBF) Explained

      11.9: Reliability Explained

      Chapter 12: Automating Preventive Maintenance through CMMS

      12.1: Maximizing the Use of CMMS

      12.2: What CMMS Should Provide for PM

      12.3: CMMS Access for the Storekeepers

      Chapter 13: FAQS and Tips on Preventive Maintenance

      13.1: Frequently Asked Questions on PM

      13.2: Tips on Implementing Preventive Maintenance

      Chapter 14: Improving Existing Preventive Maintenance Program

      14.1: Improving Existing Preventive Maintenance in our Industry

      14.2: Improving Routine Preventive Maintenance Inspection

      14.3: Improving Major Preventive Maintenance Shutdown

      14.4: Improving Scheduled Greasing Practices

      14.5: Procedure for Conducting Functionality Inspection on Protective Devices

      Chapter 15: The Conclusion

      15.1: Treat Maintenance as a Business

      15.2: Solutions to the Top 10 Problems on PM

      15.3: Every Function has Their Responsibility on PM

      Appendix A: Answers to Preventive Maintenance Quiz

      Appendix B: RSA Maintenance Courses

      Appendix C: PMS Training Course Details (2 Days)

      Serving Maintenance Mankind Worldwide

      Bibliography

      Glossary on Maintenance

      RSA Maintenance Books Collection in Series

      Acknowledgment

      FIRST, I WOULD LIKE to thank all my students who have attended my training in the past.  I always believe with all my heart that training is a two-way process.  I have to admit that I also learned a great deal from the people I taught in the past.  I hope that the knowledge gained from reading this book enlightens the reader in doing Preventive Maintenance the right way and that industries benefit from their PM activities.

      Special thanks to my wonderful family especially my three kids: Marie Vic, Kathleen Kay, and Christian Joseph, my wife, Marites, and my granddaughter Kalie.

      I would like to mention my mom Cecilia Angeles who recently passed away this July 2021 for the love, care, values, moral support, and wisdom that this wonderful woman has provided me throughout my life.  To me, she is the greatest mom I could have and I could not ask for more.  She also edited my first three books on World Class Maintenance Management, The 12 Disciplines, Maintenance – Roadmap to Reliability and Reliability – A Shared Responsibility for Both Operators and Maintenance.

      Lastly, I would like to thank God Almighty for allowing me to complete this book.  May he grant me the time and wisdom to complete the remainder of the books that still need to be written which I hope to serve as my small way of contributing to the knowledge and wisdom to all maintenance mankind in industries.

      Trust in the Lord with all your heart, and lean not on your own understanding, in all your ways, acknowledge Him, and He will make your path straight – Proverbs 3.5

      About the Author

      ROLLY ANGELES is a seasoned technical and international reliability and maintenance trainer and book author.  His portfolio of reliability and maintenance training includes maintenance management and reliability courses on Total Productive Maintenance (TPM), Planned Maintenance, Autonomous Maintenance, Lubrication Strategy, Tribology, Oil Contamination Control, Condition-Based (CBM), Predictive Maintenance, Reliability-Centered Maintenance (RCM), Root Cause Failure Analysis (RCFA), Planned Maintenance, World Class Maintenance Management (WCM), Meaningful Measures of Equipment Performance, and more.

      Rolly is a graduate of Mechanical Engineer from Mapua Institute of Technology in the Philippines, batch 1985, and passed the Licensure Board Examination the following year in 1986.  With more than 30 years of solid experience, he had worked in various industries from shipping, woodworking, foundry, cast-iron machining, assembly lines, semiconductor manufacturing, and the mining industry. From 1994 to 2002, Rolly worked as a TPM senior engineer at Amkor Technology Philippines, a Multi-National company engaged in the manufacture of integrated circuit products, and spearheaded Amkor’s Planned Maintenance Organization, composed of maintenance managers and engineers.  He was responsible for the dramatic reduction of their machine’s unplanned breakdowns in their TPM journey as well as RCM implementation on their Facilities Air Handling Units (AHU) and their sub-station equipment.  Here is where he had gained hands-on experience and understanding of both TPM and RCM, respectively.  His last corporate employment was in 2002, where he worked as a technical training specialist at Lepanto Consolidated Mining Industry.  In 2005, Rolly retired early from the industry and decided to establish his own consulting business, RSA Reliability and Maintenance Consultancy Firm, where he dedicates his time and passion to working as an independent reliability and maintenance consultant.  His email is [email protected] and his website is https://www.rsareliability.com.  Rolly has written the following books in a series that is all about his passion for Reliability and Maintenance.

      • Volume 1: World Class Maintenance Management – The 12 Disciplines

      • Volume 2: Maintenance – Roadmap to Reliability

      • Volume 3: Reliability – A Shared Responsibility for Both Operators and Maintenance

      • Volume 4: Cutting–Edge Maintenance Management Strategies

      • Volume 5: Problems and Solutions on MRO Spare Parts and Storeroom

      • Volume 6: Lubrication Tactics for Industries Made Simple

      • Volume 7: Decoding Reliability-Centered Maintenance Process for Manufacturing Industries

      • Volume 8: RSA Reliability and Maintenance Newsletter Vault Collection, Subscribers Edition

      • Volume 9: Investigating Equipment Failures through Root Cause Failure Analysis

      • Volume 10: Maintenance Indices – Meaningful Measures of Equipment Performance

      • Volume 11: Implementing Preventive Maintenance for Industries the Right Way

      Take Quiz on Preventive Maintenance Part 1

      1. IN RCM THE ACTIVITIES of performing inspections whether through the use of human senses or gauges will default to

      a) Preventive Maintenance Tasks

      b) Predictive or On-Condition Tasks

      c) Scheduled Maintenance Tasks

      d) Failure Finding Tasks

      2. The Basic Equipment Condition includes cleaning the equipment, proper lubrication, addressing leaks and

      a) Parts replacement

      b) Overhauling the machine

      c) Tightening of Bolts

      d) Extending parts' lifespan

      3. Other terms to denote Condition-Based Maintenance are also known as

      a) Reliability-Based Maintenance

      b) Predictive Maintenance

      c) On-Condition Tasks

      d) Non-Destructive Tests

      4. PM will only apply to patterns (____) of the six failure pattern

      a) Pattern D

      b) Patterns A, B, and C

      c) Patterns D, E, and F

      d) Only Pattern F

      5. According to the author, the best people suited for the role of maintenance planners would be the

      a) OEM or Vendor

      b) Reliability People

      c) Engineering

      d) The Rolling Stones (People with White Hair)

      6. In RCM, Run to Fail Tasks are not recommended for failures consequences which will result to

      a) Operational Consequences

      b) Hidden Consequences

      c) Safety and Environmental Consequences

      d) Non-Operational Consequences

      7. The best approach for determining the interval for replacement and overhauls will be the use of

      a) Age Exploration Method

      b) Using MTBF

      c) Using On-Condition Tasks

      b) Using Guestimates

      8. In RCM, Preventive Maintenance Task will include Schedule Restoration and

      a) Scheduled Discard Tasks

      b) Calibration

      c) Inspection for Hidden Devices

      d) Inspection through the Use of Human Senses

      9. If 80% of 100 impellers or more will reach a lifespan of 2 years, the best maintenance tasks to perform will be

      a) Preventive Maintenance

      b) Predictive Maintenance

      c) Failure Finding Tasks

      d) On-Condition Tasks

      10. Preventive Maintenance is designed to capture

      a) Infant Mortality Failures

      b) Random Failures

      c) Hidden Failures

      d) Age-Related Failures

      11. The most feasible maintenance tasks for failure modes that will provide signs or symptoms that it is on the verge of failing will be

      a) Predictive Maintenance Tasks

      b) Corrective Maintenance Tasks

      c) Scheduled Overhaul Tasks

      d) Scheduled Restoration Tasks

      12. These maintenance tasks can be integrated with Preventive Maintenance to minimize the chances of Infant Mortality Failures

      a) On-Condition Tasks

      b) Precision Maintenance

      c) Corrective Maintenance

      d) Redesign or Modification

      13. In determining the interval for conducting Failure Finding Tasks or Functionality Inspection, the following are needed, Availability and (____).

      a) MTTR

      b) MTBA

      c) MTBF

      d) OEE

      14. What we are looking for in conducting Predictive Maintenance tasks is to establish

      a) Root Cause of Failure

      b) Structure of Failure

      c) P-F Interval

      d) MTBF and Failure Rate

      15. In RCM, the term No Scheduled Maintenance refers to

      a) Run to Fail

      b) Breakdown Maintenance

      c) Corrective Maintenance 

      d) Reactive Maintenance

      16. One unique feature of implementing an operator’s Autonomous Maintenance is the application of;

      a) MTBF Analysis

      b) Redesign and Modification

      c) Poke-Yoke

      d) Visual Controls

      17. A Preventive Maintenance Indicator that will indicate the percentage of completed tasks compared to the overall Scheduled Planned tasks is;

      a) PM Compliance

      b) PM Effectiveness

      c) Replacement Asset Value (RAV)

      d) PM versus Breakdown Ratio

      18. According to the survey on Preventive Maintenance, the top problem on Preventive Maintenance is;

      a) PM is waived by operations

      b) Lack of training

      c) Infant Mortality Failures

      d) Ageing Workforce

      19. One technique to reduce infant mortality failure is to adapt;

      a) Preventive Maintenance

      b) Precision Maintenance

      c) Corrective Maintenance

      d) Proactive Maintenance

      20. According to the author of this book, which Preventive Maintenance tasks are prone to human errors?

      a) Calibration Tasks

      b) Replacement Tasks

      c) Overhauling Tasks

      d) Routine Inspection Tasks

      21. An Oil Analysis test to determine that a part or item is starting to wear out is by monitoring the oil thru;

      a) Spectroanalysis and Ferrography

      b) TAN/TBN

      c) Particle Counter

      d) Absolute Viscosity Test

      22. The main cause of Infant Mortality Failures is,

      a) Operator Error

      b) Human Error

      c) Improper Tools Used

      d) Delayed Delivery of Spare Parts

      23. MRO Analysis which tracks the movement of Spare Parts is

      a) VED Analysis

      b) SDE Analysis

      c) ABC Analysis

      d) FSNO Analysis

      24. The secret to the success of Autonomous Maintenance will be the

      a) Maintenance Planner

      b) JIPM Consultant

      c) Planned Maintenance

      d) Quality Maintenance

      25. This Oil Analysis instrument will indicate the rate of wear for mechanical parts inside the equipment

      a) Particle Counter

      b) NOACK Volatility Test

      c) Karl Fisher Titration Test

      d) Ferrography and Spectroanalysis

      26. For industries implementing Autonomous Maintenance, the longest step will be

      a) Step 1: Initial Cleaning

      b) Step 2: Address Sources of Contamination

      c) Step 3: Establish Cleaning and Lubrication Standards

      d) Step 4: Develop Equipment Inspection Standard and Training

      e) Step 5: Autonomous Maintenance Standards

      f) Step 6: Systematic AM and Manage the Workplace

      g) Step 7: Practice Full-Self Management

      27. When implementing Autonomous Maintenance, consolidation of maintenance tasks for operators and maintenance will happen on Step;

      a) Step 1: Initial Cleaning

      b) Step 2: Address Sources of Contamination

      c) Step 3: Establish Cleaning and Lubrication Standards

      d) Step 4: Develop Equipment Inspection Standard and Training

      e) Step 5: Autonomous Maintenance Standards

      f) Step 6: Systematic AM and Manage the Workplace

      g) Step 7: Practice Full-Self Management

      28. What makes RCM implementation unique and more precise is that it derived the maintenance task based on.

      a) OEM recommendations

      b) Operating Context

      c) Production Needs

      d) Government Recommendations

      29. According to the Circadian Rhythm most human errors occur during the following;

      a) Normal time

      b) Day Shift

      c) Morning Shift

      d) Night Shift

      30. For components with redundancies or standby, the recommended switching interval between the duty and standby should be;

      a) Weekly

      b) Monthly

      c) Duty to run for 6 months and Standby to run for 1 month

      d) Run the duty until it fails and switch to standby

      Take Quiz on Preventive Maintenance Part 2

      1. IT IS RECOMMENDED that the Maintenance Planner should just be part-time so that they can perform other tasks on maintenance

      a) True

      b) False

      2. PM is designed to address both random and infant mortality failures.

      a) True

      b) False

      3. A good PM program will eliminate all breakdowns on the equipment.

      a) True

      b) False

      4. All parts after consistent use will reach a point of wear and tear.

      a) True

      b) False

      5. A bearing that fails randomly at any given period is likely a candidate for Preventive Maintenance scheduled replacement.

      a) True

      b) False

      6. To be more effective, both Precision and Predictive Maintenance should be integrated into the Preventive Maintenance Structure.

      a) True

      b) False

      7. All critical parts should be stocked in the storeroom.

      a) True

      b) False

      8. The best indicator to measure the effectiveness of Preventive Maintenance will be PM Compliance.

      a) True

      b) False

      9. All identical equipment with the same model, maker, and vendor will receive the same maintenance tasks whether these are weekly, monthly, quarterly or yearly tasks.  This means that the PM task needs to be identical since the equipment is the same.

      a) True

      b) False

      10. One of the reasons why Preventive Maintenance is costly is that it uses the concept of JIC or Just In Case and may replace parts that are still in working condition.

      a) True

      b) False

      11. According to the Author of this book, maintenance is a profit center?

      a) True

      b) False

      12. According to the book on TPM World Congress, the number 1 reason most TPM initiatives fail is due to a lack of management support and commitment.

      a) True

      b) False

      13. According to the author of this book, the decision on whether to stock or not to stock parts in the storeroom will be based on the criticality of the part or item.

      a) True

      b) False

      14. According to the author of this book, the most important KPI or indicator for the storeroom is the inventory accuracy which should be 98% and above.

      a) True

      b) False

      15. According to a survey by James Reasons and Alan Hobbs, most human errors in Preventive Maintenance occur during the reassembly process of overhauls.

      a) True

      b) False

      16. Planners should focus on future works and not on reactive works.

      a) True

      b) False

      17. In RCM, inspection using the human senses is considered to be part of the On-Condition tasks.

      a) True

      b) False

      18. The best course of action in deriving the Preventive Maintenance tasks of our equipment and assets is to follow OEM recommendations.

      a) True

      b) False

      19. OEE is a good measurement to indicate the effectiveness of executing PM Tasks.

      a) True

      b) False

      20. A CMMS software is much bigger in scope than an EAM or Enterprise Asset Management software.

      a) True

      b) False

      Preface: Those Were the Times

      WHEN I GRADUATED IN 1985, finding work was difficult and scarce during that time.  A single position of cadet engineer will have at least a couple of hundred applicants or more.  Just imagine your chance of being selected for the job.  I still remember typing my resume and sending postal mail.  The majority of the time, the industry will reply via postal mail which I will receive in a couple of weeks indicating that they currently have no opening.  There was no internet during that time and every Sunday I need to buy a newspaper called Manila Bulletin since this is where most industries will post their job vacancies.

      John, a friend of mine in high school told me if I wanted to work as an apprentice in their ship in the engine room as his Dad owns a big shipping business.  We both came from the same high school at Don Bosco Makati.  His father interviewed me and wanted me to act as a Preventive Maintenance Specialist (although in real life, I worked as an Oiler).  I do not know what it meant but it was something nice to hear from anyone’s ear and I accepted the offer.  We work in shifts and there were 6 shifts in a day where I worked from 4 am to 8 am and from 4 pm to 8 pm again in the evening.  The other oilers were experienced people and I was new and it was my first taste of work.  They always advised me to look dirty so that the Chief Engineer (the highest paid person from the engine room) would think that I am working my sweat out.  I followed their advice and place some black diesel oil in my overhauls.  When we need the Chief Engineer in the engine room, I make sure to pour some old black diesel oil in my hands before knocking on his room making sure the oil stains will mark his door.  Those were the times.  CMMS, EAM, or these smart sensors today or any form of automation does not exist and we do everything manually.  When I enter the engine room, we need to perform a walk-around inspection of the generator making sure it contains fuel, check the main fuel tank of the ship, inspect the bulbs to ensure they are working, and all those kinds of stuff.  There were 2 Mitsubishi DAIYA Diesel Engines as the ship has a twin-propeller.  We experienced problems a few times where all engineers and oilers needed to be in the engine room since only one engine is running which means that only one propeller is functioning cutting the speed of the ship in half.  When this happens, the ship’s Captain will go down to the engine room asking how much time is expected for the other engine to run.  It was always a heated argument between the Captain and the Chief Engineer.  After a year of working on the ship, I decided that I would be better off working on land than on the sea.  This was where I first experience myself working in maintenance.

      After working on the ship, I was finally hired in a plant that manufactured sewing machines and was assigned to the woodworking station, where we have all sorts of cutting and sanding machines for knock-down types of furniture.  The same advice has been given to me by those pioneer supervisors that my clothes need to be dirty at all times so that the Operations Manager would think that I was working my sweat out once again.

      Sometimes if I come to reminisce about those times, we were always reactive.  We have no standards and our only goal in life on the ship is to bring the ship from one port to another at all means.  I remember one oiler placing an engine oil in the gearbox in which his reason is that the machine is better off with oil than none.  Time had passed and with all the technology, information, internet, and books on maintenance (my books included), it seems that little or nothing has ever changed and the majority of industries are still reactive.  I hope that it would not be the case in the distant future for industries.  This is the main reason why I decided to write this book about Preventive Maintenance.

      This book refers to Discipline Number 5 based on the original book I wrote in 2009 on World Class Maintenance – The 12 Disciplines.  Sharing my thoughts about this book, I think that I should have written this book before my other books since this is one of the basic disciplines.  Writing this book is quite challenging as I need to reminisce about my experiences, close my eyes and think of what is really happening right now in industries.  Despite so many consultants (Myself included), experts, training, webinars, information, automation, and publications about maintenance, the truth is that the majority of industries are still reactive.  Almost all industries have their Preventive Maintenance, but still, many problems emerged and the question is can we do something about it.  Many maintenance people from industries are not satisfied with their current Preventive Maintenance even if they are complying with every single maintenance task listed.  My sole intention in writing this book is to provide a guide and direction to help maintenance in industries get the results in doing the correct Preventive Maintenance on their equipment and assets.  In today’s digitalization era, and with all these advanced CMMS and EAM software, apps, technology, cloud, smart sensors, Industrial Internet of Things, and automation, the majority of industries are jumping on the bandwagon thinking that these technologies will optimize their asset.  I have nothing against technology, but what I am stating is that everything will boil down to one thing and that is addressing the basics first.  The goal and objective of having Preventive Maintenance is to prevent or anticipate a failure or breakdown from happening first.  The keyword in this case is being first.  This means that we need to perform an activity or task before failure happens.  But the thing is we need to be precise in what failures can be addressed by PM since not all failures can be prevented in the first place.  This book includes 15 chapters and is summarized accordingly.

      Chapter 1: Changing The Way We Think About PM:  Explains the traditional belief of most maintenance people in industries about PM.  This is one of the main reasons why industries still remain reactive.  Another important topic in this chapter is an updated count of the top 10 problems on PM.  This survey was consistently being done religiously during my training classes where the delegates came from different industries, countries, cultures, and races where they select the top 3 problems that currently exist in their plant.  Learn why Preventive Maintenance is costly in most industries and what can we do about it.

      Chapter 2: Understanding The Concept of Preventive Maintenance: Decipher what Preventive Maintenance is all about.  This chapter also unravels the process of wear, how it occurs, and the most common types of wear that can occur on mechanical components.  A thing of interest is that there is a wide range of terms and nomenclatures industries used for the different maintenance tasks.  A good example of this is the term Outage where which is a common term for power plants.  This chapter also explains the role of different people in the maintenance organization and how they are all connected to serve a common goal.  This means that a failure of one will be a failure of the entire maintenance organization.  Just like a chain, its strength lies in its weakest link.

      Chapter 3: Building a Solid Preventive Maintenance Structure in the Plant:  Clarifies the three main elements of a Preventive Maintenance Structure, which include Preparation, Execution, and Feedback.  The preparation is a list of activities that need to be done before executing Preventive Maintenance.  The execution involves the different maintenance tasks performed on Preventive Maintenance.  The feedback is the activities done after the PM has been executed so that we can further improve the way we execute PM for future works.

      Chapter 4: Planning and Scheduling for PM:  Clarifies the concept of planning and its role in PM.  While most planners in industries are overwhelmed and drowned by the number of repair works that must be done, what is important is that planners should focus more on future works and not on reactive works.  Planning is not always perfect, it is a continuous process that can be improved through feedback from the people who execute the PM tasks.  What is important is that the planner should communicate and collaborate with the PM crew continuously since these are the people who will carry out the task.  If there are adjustments that need to be made to the plan, then this must be looped back to the planner.

      Chapter 5: Integrating Precision Maintenance in PM: This chapter deals with the subject of Precision Maintenance and how it can be integrated into conducting PM.  It also discussed the main requirements needed to adopt Precision Maintenance effectively in the plant.  Training is very important because this is where we acquire the knowledge to build the skills and develop mastery over the subject.  Mastery is achieved once we can transfer our knowledge to other maintenance people in the organization.  Precision Maintenance is not actually a maintenance task such as PM or PdM.  Still, it should be included and integrated as part of Preventive or any other tasks on maintenance, including repair and what benefit it can provide if Precision Maintenance is implemented correctly in the plant.  The author also believes that implementing this maintenance strategy will definitely reduce infant mortality as well as random failures.  Precision Maintenance simply means that whoever is performing the task whether the person is the most or least experienced in the craft should provide the same outcome and results.

      Chapter 6: PM Interval, Are We Doing PM Too Late or Too Soon?  While many industries derived their maintenance interval from guestimates or OEM recommendations, this chapter provides a summary on how to determine the correct interval for the different tasks on maintenance such as routine Preventive Maintenance replacement, scheduled overhauls, greasing bearings, an interval for failure finding tasks, or functionality inspections, frequency of switching interval for redundant components, and interval for performing Predictive Maintenance tasks on the equipment and assets.  This chapter also explains why MTBF cannot be used to determine the interval for PM overhauling or replacements.  Lastly, we also explain how we can further refine several PM tasks.

      Chapter 7: The Role of MRO Spare Parts on PM: MRO Spare parts and Storeroom will play an important role in Preventive Maintenance.  This means that if a part is not available for PM the PM will stall.  The most important thing to consider in the Storeroom is the lead time to deliver the parts needed by the user.  This chapter also covers several factors before stocking them in the storeroom.  An MRO Algorithm or Decision diagram is provided with sample case studies to decide if parts need to be stocked or not inside the storeroom.  Practical tips to shorten the travel time to the storeroom are provided in this chapter.

      Chapter 8: Involving Operators in Maintenance: Explains the importance of having operators that are knowledgeable about the equipment.  This chapter also discusses the basic maintenance tasks and activities the operator should be doing, such as routine lubrication, cleaning, and having equipment with no missing or loose bolts and no leaks.  Three standards will be performed by the operator which will include cleaning, lubrication, and inspection standards.  Once these standards are finalized, they will be consolidated with the PM task so that further duplication can be avoided.  This Chapter also explains the key secret to implementing Autonomous Maintenance successfully and the transformation of operators from just operating to those who know their equipment intimately.  Autonomous Maintenance will take time to implement, but if correctly implemented, then it can transform operators from those who are merely routine switch flickers to those who are empowered.

      Chapter 9: The Role of Predictive Maintenance on PM: This chapter explains the concept of Predictive Maintenance tasks.  How it differs from Preventive Maintenance.  Why is the P-F interval important to any of these Predictive Maintenance users?  This chapter also explains a slight difference between Condition-Based Maintenance and Predictive Maintenance.  Other topics covered in this chapter include vibration monitoring, things to consider when buying infrared thermography, ultrasonics, and the benefits of conducting an oil analysis program.  Finally, we end this chapter with the crucial role Predictive Maintenance will play to make Preventive Maintenance more effective.

      Chapter 10: Deriving the Maintenance Tasks:  RCM and other streamlined versions can be used to develop and derive the PM tasks but the starting point is to understand how the equipment will be operated in the plant.  This is called the operating context or the condition in which the equipment will be operated.  Another important point to consider is that all maintenance tasks should address a particular failure mode and where to source these failure modes.  This chapter also details what the PM task should include as well as the different functions that will be involved in executing Preventive Maintenance

      Chapter 11: Measuring PM Effectiveness and Performance: This chapter examines the different maintenance indicators that can be used to measure our efforts in Preventive Maintenance such as PM Compliance, PM Effectiveness, Ratio of Preventive Maintenance versus Breakdown Maintenance, Maintenance Cost, Percentage of Maintenance Cost to RAV (Replacement Asset Value), Maintenance Backlog, Wrench Time, MTBF and Reliability.  Also detailed in this chapter are some weaknesses of these measurements.  Some useful measurements and indicators for Predictive Maintenance are likewise explained.

      Chapter 12: Automating the PM Tasks and Performance:  Explains that although CMMS or EAM software can benefit maintenance, most industries that have this software are often underutilized.  What is important is to understand what is it that we want to automate and if the system is capable.  This maintenance software such as CMMS is only as good as what we populate in them.  This chapter also illustrates what are the important things and information that should be automated for Preventive Maintenance besides the Work Orders generated.  Also included are the important things to automate in the storeroom that is needed for Preventive Maintenance.

      Chapter 13: FAQs and Tips on PM is a collection of Frequently Asked Questions and answers on Preventive Maintenance.  Some of these questions have been raised during my training in the past.  This chapter also provides some helpful tips that industries can apply to improve their existing Preventive Maintenance activities.

      Chapter 14: Improving Existing Preventive Maintenance Program: This chapter provides detailed guidelines for improving the current and existing Preventive Maintenance for industries which includes inspection activities, routine, and major Preventive Maintenance shutdown, routine greasing, and procedures for conducting a functionality inspection for protective devices.

      Chapter 15: The Conclusion:  Finally, this chapter concludes that maintenance should not be treated as a cost or even as a profit center because maintenance is both.  Rather it is better if we treat maintenance as a business since in any business there will always be an investment but what is important is that whatever we invest should have a return or payback since this is where we generate the profit.  This chapter conceals solutions to the top ten problems on PM and lastly, it states that PM is not only for the planner and those who will execute them but several functions of the organization also have their role and responsibility that they need to understand.

      Chapter 1

      Changing The Way We Think About PM

      1.1: The Traditional Belief in Preventive Maintenance

      THE TRADITIONAL BELIEF of most maintenance people is that if a certain part is used consistently, it will definitely reach a point where the part will eventually wear out; therefore, overhauling or replacing the part before it fails on an assumed schedule will ensure the equipment's reliability.  By doing this, the equipment will continue to run and operate as expected.  The truth is that not all parts will eventually wear out.  Just like people, especially during this covid 19 pandemic days, not everyone will reach their natural life expectancy.  Meaning not everyone will become a grandfather or grandmother.  This means that not all human beings from the United States or other countries will reach 79 years; others will die young, while others will even die before they will be born.  Japan can be considered one of the most advanced countries in the world, but its rate of people committing suicide is also high.  This means that these people will not reach their natural lifespan.  Just like in industries, the problem is simple, but people make it complicated.  In maintenance, we assume that all parts will eventually wear out; that is why our primary defense on our equipment is to perform intrusive Preventive Maintenance to prevent failures and this had been the culture of the industry since the beginning of time.  The more breakdowns, the more repairs are experienced and the people’s time is eaten up by troubleshooting the equipment, which has been their day-to-day task in the plant.

      In figure 1.1, let us assume that the x-axis represents the time or the period, while the y-axis represents the rate of wear or rate of deterioration.  The traditional belief on maintenance is that if the equipment is running continuously, 7 days a week, 30 days a month, 365 days a year.  Maintenance will assume that definitely, something will fail.  Maintenance will assume that the failure will happen at Point 4 and because of this thinking, maintenance will create a contingency plan and specify several maintenance tasks that should be done on the equipment.  They will execute these activities either on Point 2 or Point 3.  What is important is that these tasks must be done before the said failure.  These activities will include replacement and overhauls, where the equipment will be stopped completely for these tasks to commence.  What maintenance is thinking is that these parts should be replaced before they fail so that production will not be interrupted.  However, when these tasks are finally completed and the machine is returned back to the operators, it seemed that the operators are having a hard time running their equipment.  What’s on the mind of the operator is that, if maintenance did not touch this I bet this will be running smoothly without any problems.  Technically, the reason why we performed these tasks is for the equipment to run smoothly, but the problem is that the opposite happens.  So how can we explain this phenomenon?  In fact, if the reader is from maintenance, perhaps you have experienced this event yourself.  If yes, the truth is you are not alone.

      FIGURE 1.1: TRADITIONAL Belief in Preventive Maintenance -1

      Everything can be traced back to one thing, and that is our traditional belief in maintenance.  According to the book of John Moubray on RCM II page 143, he quotes that it is also borne out by the machine operator who said that every time maintenance works on it over the weekend, it takes up to Wednesday to get it going again.  If we analyze this case, the scheduled maintenance tasks will be done on a weekend, which is a Saturday, and Sunday, but the machine will take up to Wednesday to run smoothly.  This means that the operators are having a difficult time running the equipment on Monday and Tuesday.  In reality, many operators experienced that after performing scheduled Preventive Maintenance on their equipment, they are having a hard time operating their equipment and machines.  But isn’t it supposed to be that it should be the other way around?  If we performed a scheduled Preventive Maintenance in our equipment, it should be running smoothly, but the thing is right after conducting Preventive Maintenance tasks, especially when replacement and overhauling are present, operators complain that they find it difficult operating the equipment.  These early failures are called infant mortality failures.  Many factors contribute to infant mortality failures, but the main contributor to Infant Mortality Failure is human error.

      FIGURE 1.2: TRADITIONAL Belief in Preventive Maintenance -2

      There are two common types of human errors that can happen in this case.  It can either be a slip or a lapse.  A slip occurs when somebody does something incorrectly; for example, an electrician wires a motor incorrectly that it runs backward.  These are human actions that take place which was not intended.  The occurrence of a lack of one's train of thought is derived from unconscious behavior.  On the other end, lapses occur when someone misses a key step in a sequence of events or activities.  For example, a mechanic leaves a tool behind after working in a machine or simply forgets to fit a key component while reassembling it.  Some say it has something to do with the process of aging as we grow old.  Both slips and lapses happen because the people were distracted, preoccupied, thinking of something else, or the person was simply absent-minded.  Putting this in another perspective, a slip occurs when you need to perform step 1, step 2, step 3, step 4, and step 5, but what you did was step 1, step 2, step 3, step 5, and step 4.  A lapse occurs when you need to perform step 1, step 2, step 3, step 4, and step 5, but what you did was step 1, step 2, step 3, and step 5, where you missed out on step 4.  According to James Reasons and Alan Hobbs on Managing Maintenance Error, 64.5% of human errors associated with maintenance tasks involved the omission of necessary maintenance tasks.  Their findings were from the airline industry.  In a series of interviews with the maintenance aircraft crew, they conducted throughout

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