Equipment Maintenance Plans

Equipment Maintenance Plans are developed for clients to ensure proper utilization of resources by reducing unscheduled maintenance and down time, as well as decreasing unnecessary maintenance (e.g. – replacing bearings on a particular schedule without examining their condition).

Using known equipment failure modes, equipment maintenance plans tell you what technologies to apply, where to apply them and how to optimize available resources.

Starting with a walkdown of equipment and development of a criticality matrix, we can ensure your asset health is up and running.

SubjectDescription
PrinciplesA system which prioritizes maintenance activities, using a combination of historical data and scheduled monitoring. By routinely verifying ‘typical’ equipment conditions – i.e. vibration levels, oil temperatures, etc – one can easily identify wear on components and schedule ‘smart maintenance’ in lieu of waiting until complete failure of the equipment or wasting resources doing unnecessary work.

The scientific principles used in this method include:
Written procedures
Data collection scheduling
Data Collection and sorting
Analysis of the data collected to create a predictive maintenance schedule

How is it used and for what purpose?Equipment Maintenance Plans are used to ensure proper utilization of resources, by reducing unscheduled maintenance and down time, as well as decreasing unnecessary maintenance (i.e. – replacing bearings every shutdown, ‘just in case’)

This process can be used in any workplace, and is even being utilized in vehicles (i.e. - % Oil Life is a common feature on a new car. Oil is only changed when the lifecycle of the oil is spent, not simply every X distance)
Equipment Maintenance Plans are currently being used in all industries including the Pulp and Paper Industry, Automotive, and Petrochemical, to name a few.
Applicable Codes and StandardsCodes and Standards very by industry, but can include: Vibration Standards, ASME, ASTM, IEEE, etc
Form of reportThe reporting style can very drastically depending on the requirements of the industry and the criticality of the piece of equipment (Is this machine required for production, or can the process continue with the machine down?). Common reporting style includes maintaining a database with current and historical data, monthly progress reports and periodic reports to address any immediate issues.
AdvantagesBetter use of maintenance assets and results in less unplanned downtime. Less cost of repair when failures are identified.
LimitationsRequires routine data collection and a program setup/monitoring by qualified engineer.
AlternativesThere are 2 other types of maintenance plans commonly in use which are the ‘Run to Failure’ maintenance and ‘Interval based’ maintenance.

Run to failure is the maintenance style whereas a piece of equipment is run until failure, broken components or the entire machine is repaired or replaced, and then production continue.

Planned maintenance is the style in which every ‘x’ cycles components are changed or replaced, regardless of wear. With this type of maintenance equipment is not typically monitored on a regular basis, therefore unplanned outages are still common.

Technician certificationReliability Engineers
Rope access applicable? No