Boosting-Uptime-Your-Guide-to-Preventive-Maintenance.pptx

Presentation on Preventive Maintenance

1. Boosting Uptime: Your Guide to Preventive Maintenance Unlock peak performance and extend asset lifespan with a robust PM program.

2. The PM Program at a Glance A successful Preventive Maintenance (PM) program is built on these foundational pillars: Asset Register Comprehensive database of all equipment, including criticality ratings. Standard PM Tasks Clear, repeatable procedures for maintenance activities, defining scope, frequency, and safety. Calendar & Work Orders Scheduled tasks, assigned technicians, and documented work execution. Spare Parts & Tools Ensuring critical components are on hand to minimize downtime. KPIs & Feedback Metrics to measure program effectiveness and continuous improvement loops. Governance Defined roles, responsibilities, and processes for program oversight and change control.

3. 10 Steps to PM Rollout: Simple & Effective Implement your PM program with this phased approach for maximum impact. 01 List Assets & Criticality Identify all assets and classify them (High, Medium, Low) based on operational impact. 02 Define Failure Risks For critical assets, outline common failure modes and their consequences (e.g., equipment downtime, safety hazards). 03 Build PM Library Create concise procedures for each task, including frequency, duration, skill required, and PPE. 04 Standardize Checklists Develop easy-to-use, short checklists with clear pass/fail criteria and space for remarks. 05 12-Week Rolling Schedule Assign technicians and target dates. Review and re-plan weekly; never let PMs lapse. 06 Utilize Work Orders Document every PM as a work order, tracking start/finish times, parts used, downtime, and supervisor sign-off. 07 Stock Spares Maintain minimum levels for high-risk, frequently used parts like filters, belts, and sensors. 08 Log Findings & Fix Roots Convert recurring issues from PMs into corrective actions; update PM tasks as new failure patterns emerge. 09 Track Key Performance Indicators Monitor PM compliance, Mean Time Between Failures (MTBF), and the ratio of emergency vs. planned work. 10 Establish Governance Conduct weekly huddles to review overdue PMs, parts blockers, safety issues, and emerging risks.

4. Real-World Scenario: Small Facility Let's apply the PM framework to a typical small industrial facility: Assets: 10 kW Hybrid Inverter, 51.2V LiFePO₄ Battery Bank, 5-ton Rooftop HVAC, 40 kVA Diesel Generator, 7.5 kW Air Compressor. Location: Karachi (demands robust heat management and dust control protocols).

5. Top Risks & PM Tactics: Small Facility Targeting critical assets with specific, proactive maintenance: Hybrid Inverter (Critical) Monthly visual inspection, terminal torque check, alarm log review, fan test, heatsink cleaning, firmware status check. LiFePO₄ Battery Bank (Critical) Weekly BMS/alarm review, temperature & SOC window checks, busbar inspection, and room ventilation assessment. HVAC (Medium) Monthly filter and coil cleaning; ensure drain lines are clear to prevent blockages and water damage. Diesel Generator (Critical) Monthly 15-minute no-load run; check fluids, battery, and for leaks. Quarterly oil and filter change. Air Compressor (Medium) Monthly oil level check, condensate drain, belt inspection, and intake filter cleaning.

6. Roles & Responsibilities (Light RACI) Clear roles ensure accountability and smooth PM execution: Technician (E/M/HVAC) Executes PM tasks and completes checklists. Reports findings and initial observations. Planner/Scheduler Maintains the 12-week PM schedule. Generates and distributes work orders. Storekeeper Manages spare parts inventory levels. Issues parts for PM and corrective work. Supervisor Ensures safety and quality standards. Reviews and signs off completed work orders.

7. Your Ready-Made PM Toolkit Streamline your PM implementation with this comprehensive Excel toolkit, designed for immediate use. Available for download.

8. Using the PM Toolkit: Quick Start Guide Maximize the utility of your toolkit with these five simple steps: 1 Customize Asset Register Replace example assets with your own, ensuring Asset IDs remain consistent. 2 Tweak PM Library Adjust steps and frequencies to align with OEM manuals and your specific operating environment. 3 Manage PM Schedule Maintain realistic assignments, re-plan weekly, and always update work status. 4 Print & Attach Work Orders Generate work orders for each PM and attach the relevant checklist page for technician use. 5 Record & Update Weekly, document compliance, urgent findings, and parts consumed. Adjust spare minimums as needed.

9. Safety First: Essential PM Rules Lock-out/Tag-out Always apply LOTO procedures before working on live or rotating equipment. Proper PPE Use appropriate Personal Protective Equipment for the task (e.g., arc-rated gloves, hearing protection). Battery Room Protocol Keep metal-free (no jewelry) and ensure adequate ventilation in battery rooms.