Developing a Maintenance Plan

• A good preventive maintenance plan starts by outlining plan goals. Ideally, include reduced production down time, worker safety and reduced repair costs as program goals. Set realistic goals and make them measurable. Keep in mind that later evaluation of the maintenance system refers back to the original goals. From the goals, determine the steps and procedures needing accomplishment. Examples include overall cost analysis, specific uses for each machine and training requirements. While initial cost analysis might show more expense in the beginning of the program for training and tools, in the end, a maintenance plan produces real savings in preventing repairs and production downtime. Ensure the system operates within a realistic budget.
  
  

Selling the Idea

• Executive and senior management must believe in the advantages of a preventive maintenance system, as they will have to approve the expenses. Operators and service personnel need to understand the necessity of proper preventive maintenance, as these are the personnel completing the tasks. One way to get the workforce on board is to have a senior manager promote the idea or develop a committee comprised of key members in the workforce to help with planning. Another is to start the new maintenance system on a critical area or machine that will show results quickly.
  
  

Define Specific Requirements

• Determine the specific tasks each machine performs in the organization. Most manufacturers' specifications for preventive maintenance intend equipment use in a temperate climate and 40-hour workweek schedule. The actual operating environment may include excessive heat or cold, extreme humidity or 24 hour-a-day operation. Additional maintenance steps may be necessary to keep equipment functioning at an optimum. Prioritize machinery for preventive maintenance based upon safety factors and cost. Give regularly used machinery and equipment the highest priority, as these have a worker safety impact and result in lost production when not functioning. Schedule maintenance for seldom-used machinery and equipment on a lower priority.
  
  

Scheduling

• After fully developing and implementing the preventive maintenance system, schedule appropriate tasks. Preventive maintenance is not a one-time event. Different levels of maintenance occur at different intervals. Schedule some maintenance for weekly intervals, such as greasing wheels or gears, or monthly such as verifying safety devices. Schedule other, more complex tasks, such as replacing seals, semi-annually or annually, depending upon manufacturer specifications. Plan scheduled maintenance during slower production times to save on cost and loss of production. Schedule annual refresher training on maintenance procedures, new techniques or modified priorities as well.