PMO - Preventive Maintenance (PM) Optimization

PMO - Preventive Maintenance (PM) Optimization

Many plants and facilities have ineffective preventive and predictive maintenance practice in place. The demand for greater asset reliability and cost reduction on has most of us turning to our PM Programs. Studies shows over 97% of PM’s are in need of Optimization.

Regardless of how a maintenance program has been developed, there is a constant need to review and update the program based on failure history, changing operating circumstances and the advent of new predictive maintenance technologies. The generic process used to perform such analyses is known as PM Optimization (PMO).

Preventive Maintenance (PM) Optimization increases equipment reliability by uniquely identifying potential gaps in PM performance and frequencies. The process lowers overall facility maintenance costs by comparing site PMs to industry best practices.

Problems with Typical Preventive Maintenance Program

  • Inadequate task descriptions
  • Low PM schedule compliance
  • Many duplicate tasks are assigned to multiple people
  • No accountability for quality PM execution
  • Often tasks are “cut and pasted” from similar equipment PMs and are not applicable to that.
  • Many PMs are simply not value-added

10 - Step PM Optimization from Arrelic

  • Prepare PMO:
    • Define systems Reliability requirement
    • Establish system criticality Ranking
    • Establish systems availability Ranking
    • Selection of the equipment and/or system, according to Reliability, criticality and availability.
  • Define System or Equipment according to Reliability Requirements:
    • Gather information about the related equipment selected.
    • Classified the information collected.
    • Established failure Mode
    • Analyze the information.
    • Analyze the failures modes of the system.
  • Review Existing PM:
    • Check every one of the existing tasks of the actual plan.
    • Check if the above failure modes are covered by the existing task.
  • Screen Task for Removal:
    • Review all tasks to decide if it is necessary to remove one or more of them.
  • Optimize Remaining Tasks
    • Optimization of the existing tasks by adding more information or modifying the existing information.
  • Fill Gaps on PM
    • Recheck each task and confirm that nothing is missing.
  • Review Manufacture Recommendations
    • Double check manufacture recommendations
  • Optimize PM Work Order
    • Modify actual PM work order
  • Implement Change
    • Apply all the changes made on site.
  • Evaluate Improvement.
    • Evaluate all changes with inspections

Advantages and benefits of Arrelic PMO?

  • 35 percent reduction in scheduled downtime hours
  • 15 percent elimination of tasks that provide no value
  • 50 percent increase in required PM task coverage
  • 80 percent increase in objective, data-driven PM actions
  • 40 percent reduction of maintenance labor hours

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