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Department of Defense

Voluntary Protection Programs Center of Excellence

Development, Validation, Implementation andEnhancement for a Voluntary ProtectionPrograms Center of Excellence (VPP CX)

Capability for the Department of Defense

Development, Validation, Implementation and Enhancement of a VoluntaryProtection Programs Center of Excellence (VPP CX) Capability forDepartment of Defense (DoD)

Department of Defense

Voluntary Protection Programs Center of Excellence

Preventive Maintenance

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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.

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What is Preventive Maintenance?

Preventive maintenance is a schedule of planned

maintenance actions aimed at the prevention ofbreakdowns and failures.

The primary goal of preventive maintenance is toprevent the failure of equipment before it actually

occurs.

Designed to:

Preserve and enhance equipment reliabilityby replacing worn components

Ensure machine failures are not the cause forworkplace mishaps.

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VPP PM Requirements

A written preventive and predictive maintenance

system must be in place VPP Federal Register Notice 65:45649-45663,

Equipment must be replaced or repaired on a

schedule, following manufacturersrecommendations

Documented records of maintenance andrepairs must be kept

The system must include maintenance of hazardcontrols such as machine guards, exhaustventilation, mufflers, control circuits and devices,etc.

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Need for PM System

A PM system aligns with asafety management programto:

Prevent injuries caused bymalfunctioning equipment Increase automation

Reduce losses due to productiondelays

Improve quality Just-in-time manufacturing Provides a more organized workenvironment. Image courtesy

of www.defenselink.mil

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Advantages of a PM System

Some advantages of a PM system include: Reduced production downtime

Conservation of assets and increased lifeexpectancy of assets (both machine and human)

Ensuring all equipment safety features arefunctioning properly

Reduced cost of repairs by reducing secondaryfailures

Quality products Identification of equipment with excessivemaintenance costs

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PM Program Risks

PM program risks couldinclude: Damage to adjacent equipmentduring a PM task

Damage due to an error inreinstalling equipment into itsoriginal location

Damage due to the installation

of new parts.

Image courtesy of www.defenselink.mil

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The Law of PMPrograms

The higher the value of plant assets andequipment per square foot of facility, the

greater will be the return.

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Things To Consider

Things to consider after completing amaintenance operations: Ensure equipment meets manufacturersspecification

Review job hazard analysis (JHA) to ensureequipment alterations or equipment maintenancedid not introduce new hazards

Conduct machine checks to ensure all features,especially safety devices, are functioning properly

Ensure employees are aware of any changes toequipment and/or operating procedures.

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A Successful PM System

Three keys for a successfulPM system: Scheduling: Should beautomated to the maximumextent possible

Execution: Should be donebefore an actual break downoccurs

Quality: Should have a formalprocess for checking thequality of repairs.

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PM Focus

PM focus should be on: Cleaning

Lubrication and inspection

Correcting deficiencies

Operation of safety devices.

Pre-determined partreplacement should beminimal and done only

where evidence clearlyindicates wear-outcharacteristics.

Image courtesy of www.defenselink.mil

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Data Absence

When PM data is missing

capture techniquesshould look at: Structural/facility

Age exploration programs

Statistical analysis Safety inspection data.

Cost should not be aprimary factor in deciding

against data collection fora PM system.

Image courtesy of www.defenselink.mil

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Preventive Maintenance Workers

Ways to motivate your PM workers include:Establishing effective training programs

Establishing inspection and preventive maintenanceas a recognized, important part of the overall

maintenance program, including follow-upsAssigning competent, responsible people to thepreventive maintenance program

Setting high standards

Publicizing reduced costs with improved up-time andrevenues and employee safety, which are the resultof an effective preventive maintenance system.

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Summary

In this presentation you learned about: Preventive Maintenance Program components

Reasons for the PM system

Advantages of a PM system

PM risks PM after action items

Successful PM system

PM focus

Ways to motivate PM workers.

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Questions?Questions?