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Another guide in this matter can be the service manual issued by the equipment manufacturer. These parts can be identified by the craftsmen and supervisors who maintain these equipment they, by their experience, know the items liable to wear or equipment maladjustments taking place under normal conditions. (iv) Special purpose-unique equipment and machines.Īfter listing the equipment requiring PM, the next step is to decide-what physical parts of each piece of equipment need attention. (iii) Process equipment such as furnaces, compressors, pumps, boosters, motors, pipings, etc. (ii) Safety equipment such as vacuum and pressure relief valves, flame and flashback arresters, fire extinguishers safety alarms, etc. (i) Material handling equipment such as cranes, lifts, conveyors, hoists, trucks, etc. In other words, a breakdown of key items would seriously interrupt production and badly affect production schedule, etc.Ī few examples of key-items are as follows: In almost all industries, there are certain key items which are more essential for continuing the production than others. Application of PM to all the items in a plant may be uneconomical. Preventive maintenance is costly, therefore one should strike a favourable balance between this cost and the cost of not utilizing PM. The entire PM programme hangs on inspections and their related duties of adjustments and repairs. It is better to tackle one section (or department) at a time or one type of machinery over the entire plant. PM programme should be built up in pieces when one piece is finished, start the next. One should not apply PM to the entire plant at once. But as the work load of PM increases, PM is transferred either to maintenance department or to a separate division of inspectors, crafts and supervisors.Īpproximate size of preventive maintenance force: For this reason, certain industries keep PM under production department. However, a perfect coordination between production department and PM personnel is highly essential for the success of the preventive maintenance practice, because PM personnel can carry out (preventive) maintenance only when production department releases the machinery for the same. The choice depends upon, again, the conditions (such as size, age, location, machinery, etc.) of the plant. (c) A separate division of inspectors, crafts and supervisors. Preventive maintenance may be taken care by: (ii) A well-conceived preventive maintenance programme contains the following elements, features or steps: It must be tailor-made-measured and cut to fit the requirements of individual industry or plant this is because all industries differ in size, age, location, machinery, resources, layout, and construction.
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(i) There is no ready-made, on-the-shelf, preventive maintenance programme for any industry. (viii) To ensure safety of life and limbs of the workmen.Įlements (or Procedure) of Preventive Maintenance: (vii) To achieve maximum production at minimum repair cost. (vi) To reduce the work content of maintenance jobs. (v) To maintain the operational accuracy of the plant equipment. (iv) To maintain the optimum productive efficiency of the plant equipment and machinery. (a) Periodic inspection of equipment and machinery to uncover conditions that lead to production breakdown and harmful depreciation. Preventive Maintenance (or PM) Involves : The underlying principle of preventive maintenance is that prevention is better than cure. It locates weak spots (such as bearing surfaces, parts under excessive vibrations, etc.) in all equipment, provides them regular inspection and minor repairs thereby reducing the danger of unanticipated breakdown. (c) Preventive Maintenance:Ī system of scheduled, planned or preventive maintenance tries to minimize the problems of breakdown maintenance. Scheduled maintenance practice is generally followed for overhauling of machines, cleaning of water and other tanks, white-washing of buildings, etc. Inspection, lubrication, servicing, etc., of these equipment are included in the predetermined schedule. Scheduled maintenance practice incorporates (in it), inspection, lubrication, repair and overhaul of certain equipment which if neglected can result in breakdown. Breakdowns can be dangerous to life and as far as possible should be minimized. Scheduled maintenance is a stich-in-time procedure aimed at avoiding breakdowns. (vii) Breakdown maintenance practice cannot be employed for those plant items which are regulated by statutory provisions, for example cranes, lifts, hoists and pressure vessels.