|Principles||A 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:
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 Standards||Codes and Standards very by industry, but can include: Vibration Standards, ASME, ASTM, IEEE, etc|
|Form of report||The 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. |
|Advantages||Better use of maintenance assets and results in less unplanned downtime. Less cost of repair when failures are identified.|
|Limitations||Requires routine data collection and a program setup/monitoring by qualified engineer.|
|Alternatives||There 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 certification||Reliability Engineers|
|Rope access applicable? ||No|