Chapter 10 - Optimizing the Preventive Maintenance Process

Abstract

This chapter presents various aspects of optimization of the preventive maintenance (PM) process. The chapter discusses a model developed for Beta for optimizing the PM process as managed by a computerized maintenance management systems (CMMS), and for incorporating predictive and proactive methods. All appropriate PMs, related procedures, overhaul or turnaround procedures should be completed. It is suggested to define the calibration requirements and intervals for each instrument. It is observed that if the instrument requires weekly calibration, it may not be suitable for its intended service and should be considered for replacement. The review of equipment histories to understand indications of potential needs and equipment condition information, not just the predictive technologies but also operator knowledge and other plant staff knowledge is emphasized. The model for optimizing the PM process also involves the systematic use of the condition monitoring technology and operator information to validate the need for PM, validate the quality of the work done, and detect early onset of failure. The proactive methodologies to eliminate the root cause of failures, minimize or mitigate the need for PM, and eliminate defects in equipment and production methods are also elaborated.