Troubleshooting Preventative Maintenance

1
Troubleshooting Preventative Maintenance

• MAIN 220
• Fall 2003
• Updated Spring 2008

2
Preventative Maintenance

• Objectives
• 6 steps Preventative Maintenance
• 8 types of Preventative Maintenance understand
  them and choose best one for troubleshooting
• reading assignments and schedule calendar for
  processes types of troubleshooting
• Chapter 19 How To Establish a 6 step PM program
• Rockis textbook chapter 18

3
6 PM Steps

• Select the Areas
• Define
• Establish Frequency of Assignments
• Prepare the PM Assignments
• Schedule PM Assignments Annually
• Expand the Program

FOR MORE INFO...
MMSM Chapter 19
4
How to Apply 6 Steps

• Select a Critical Unit
• Define PM Requirements
• Establish PM Frequency
• Prepare PM Assignments
• Schedule PM Assignments
• Expand the System

5
Ask yourself

• What is the difference between Preventative
  Maintenance and Predictive Maintenance
• What is the difference between a Work Ticket and
  a Preventative Maintenance Ticket?

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Predicative Maintenance

• Most companies base their predictive maintenance
  programs on vibration analysis or interval timed,
  visual inspection. and that is why we find
  "reactive maintenance" the norm in most plants.
  How many times have we heard the expression "I
  did not have time to do the job correctly
  (realignment, dynamic balancing, etc.) because I
  had to get the pump back on stream".
• A more sensible approach to predictive
  maintenance is to monitor the equipment for
  changes that could be destructive in the future,
  but allow you to correct them before the
  destruction starts. I spent my formative years in
  nuclear power. If, as an operator, you did
  something wrong that would be harmful to the
  atomic reactor it would "scram" and shut down
  immediately. But if you took an action that could
  be potentially dangerous, the reactor would start
  an "insertion" that would start to slowly shut
  down the reactor and give you time to correct
  what ever it was you did.

7
Common Issues

• Correct parts materials
• Machine set up for that application
• Loose belts

• Leaks in air, steam, water, power
• Dripping Lubricant
• Electric Arcing
• Changes in sound of machinery

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Work Ticket

• Used to identify the problem for the
  troubleshooter
• When
• What
• When
• Where
• Quality System to measure output

9

• RCM
• The idea is to prevent damage
• PM sheets differ than Work Tickets
• Tell when and what was prevented

10
Reliability Centered Maintenance

• RCM is "to determine the maintenance requirements
  of any physical assets (EQUIPMENT) in its
  operating context.
• This is accomplished by answering questions about
  the equipment in order to determine what type of
  maintenance strategy to employ for the asset. RCM
  provides a flow diagram that tells you what type
  of maintenance to use based on the answers to the
  questions.

11
Root Cause Maintenance

• RCA is "to uncover the underlying reasons (root
  causes) why an event (not just equipment but any
  type of event) is occurring so that the necessary
  steps can be taken to eliminate the event in its
  entirety."
• This is accomplished by analyzing the modes (the
  point at which RCM stops). RCA uses a logic tree
  that stresses verification at every level. The
  advantage is that the actual root causes that are
  uncovered are facts that have been derived from
  the verification process.