5-Day Preventive and Predictive Maintenance

This class covers the elements of PM and PdM in a 5-day format. All aspects of PM are considered in detail including engineering, economics, management and psychology.

The 5-day course offers a comprehensive foundation for any organization wanting to improve or set-up a PM system. Delegates to this course will leave with a deep understanding of PPM and will have the ability to look at, improve or design a PM system.

In addition to the learning mentioned in the 2-day and 3-day courses the 5-day course offers in depth discussions and exercises in all the major areas. If this course is given in a plant, time can be set aside to start the review and plan the improvement of the existing PM program.

  • Examples and techniques to reduce labor and material waste in PM activity
  • How to look at a task to see if it impacts reliability
  • How to gain productivity through a small change in thinking
  • How to manage PM and CM activity
  • Rating existing task lists
  • Developing task lists
  • How can you insure PMs are done as designed
  • What is the economics of Planned Component Replacement and how is it used?
  • Review examples and reports from predictive maintenance?
  • Using advanced techniques such as statistical analysis and the PF curve to optimize PM.

  1. Groundwork
    • The goal of Maintenance
    • PM, PdM Defined for this course
    • PM Report Card
    • 10 Questions
    • How much is enough?
  2. PM Basics
    • Task lists
    • Common PM tasks
    • Review common task lists
    • Other aspects of the PM system or Program
    • A special kind of failure: Hidden Failures
    • How things fail and the kind of PM needed for each failure style
  3. Introduction to Total Productive Maintenance TPM
    • TLC key to TPM
  4. World Class Maintenance

  1. The complete story of TPM
    • Installation of TPM
    • Attention to the 6 loses
    • Seven steps to autonomous maintenance
    • Meeting minutes
    • Measuring equipment effectiveness
    • Case Study in measuring equipment effectiveness
    • Exercise in choosing TPM tasks
  2. PM Details for effectiveness
    • Different types of task lists
    • Where to get the original Task List
    • PM frequency
    • PM clocks in use
  3. Advanced Concepts- PM at the next level
    • P-F Curve
    • Statistical Analysis
    • PCR
  4. Predictive Maintenance
    • Questions before you start
    • Chemical and particle Analysis Predictive tasks
    • Vibration
    • Temperature
    • Visual techniques

  1. Full Cost of breakdown
  2. P/PM Economics
    • Past Sins
    • Costs of PM system
    • Case Study: Alternatives with Cost justifications
  3. Selling PPM to management: Battle for a share of the mind
    • Selling PM to management
    • What to say when selling PM to management (identify priorities)
  4. CMMS approaches to PM and PdM
    • Thoughts on installing a PM program
    • Reporting deterioration
    • Tying CM to the PM ticket
    • Shop floor automation

  1. Review task lists brought in by class
  2. Personnel issues
    • Staffing the PM Effort
    • What kind of personality to look for in a PM inspector
    • How to insure that PMs are done as designed
  3. Get it going right
    • The big list
    • Look out; problems ahead
  4. Short Repairs and high productivity
    • Justifying short repairs
  5. Management of PM activity
    • Planning and Scheduling PM activity
    • Access to Equipment
    • Interruptive maintenance and non-interruptive maintenance
    • Metrics
    • Outsourcing PM
  6. For TPM to work you'd better be great at Training
  7. Certified operator/mechanic

  1. Reliability Enhancement Programs
    • RCM
    • PMO
  2. Task list development
  3. Task list analysis
    • Complete analysis of task lists (line by line)
  4. Action Plan