PREVENTIVE & PREDICTIVE MAINTENANCE

OBJECTIVE :

Preventive and predictive maintenance is a maintenance system which very reliable to prevent some sudden troubles or breakdown that may happened on factory’s tools/equipments. The sudden troubles are very potential things that caused a big loss in production process. The effects of this problem are some failure to achieve production target, the lack of personnel, unprepared spare parts, etc. Preventive and predictive maintenance application system starts from standard arranging, activity planning, realization supervising, and, as the finish line is, evaluating and analyzing the maintenance’s result.

PARTICIPANTS

This special course is designed for manager, supervisor, engineer, planer, foreman, and technician. Also, for those who are in operations, engineering and purchasing division and who would like to acquire an understanding of how the quality of the maintenance function affects their function.

WHAT WILL THE PARTICIPANT GET?

After completing this course, participants will be able to:

1. Develop, implement and supervise the preventive and predictive maintenance program
2. Economize the time, money and company’s resources by using sophisticated technique and method in order to optimize the affectivity of maintenance.
3. Prevent the company’s equipment and tools from damage and make the machine’s living period longer.
4. Decrease the down time
5. Increase the profit

MATERIAL OUTLINE :

1. Why Preventive & Predictive Maintenance

1. Apprising maintenance performance and effectiveness
2. Typical maintenance controls
3. Reactive maintenance
4. Anticipative maintenance
5.  Ascertainment of equipment condition
6. The need for preventive maintenance

2.     Why preventive maintenance

1. Preventive Predictive maintenance objectives
2. Preventive Predictive maintenance prerequisites
3.  Preventive maintenance feasibility analysis
4. Policies
5. PM program functions
6.  Cost impact
7. Saving potential

3. Developing the Preventive Predictive Maintenance Program

1. Assignment of organizational responsibilities typical maintenance functional assignments operational concepts
2. Equipment to be included
3. Equipment inventory sheet – examples
4. Equipment numbering concepts
5. The PM work order
6. Developing the inspection sheet
7. ECS rating sheet as cross reference
8. Sample of equipment components
9. Spare parts and material needs
10. Inspection sheet examples
11. Determining the frequency cycle
12. Frequency cycle examples
13. Scheduled frequency overview
14. Developing job safety practices – typical examples
15. Considering manual versus computerization
16. Predictive maintenance can determine maintenance requirement
17. Predictive maintenance and its applied techniques as part of the PM program
18. Vibration analysis
19.  Wear particle analyzing
20. Thermography

3. IMPLEMENTATION OF PREVENTIVE MAINTENANCE PROGRAM

1. Job planning
2. The planning function
3. Planning, Service to do
4. Job planning prerequisite
5. Planners qualifications
6. Duties and responsibilities of planners
7. The hob package
8. Line supervisors qualifications
9. Planning permits Us, to forecast, communicate and measure
10. What job should be planned
11. Time required to perform work…labor content
12. Standard defined
13. Consistency of estimating
14. Estimating methods
15. Work backlog
16. Scheduling of maintenance work
17. PERT and CPM as scheduling tools
18. Loading of the PM work order
19. Load leveling
20. Weekly scheduling
21. Manpower requirements forecasting
22. Forecasting by crew
23. Forecasting by department
24. Weekly schedule – Computer and manual example
25. Training of personnel

4. CONTROLLING THE PREVENTIVE PREDICTIVE MAINTENANCE PROCESS

1. Preventive maintenance administration
2. Planned maintenance
3. Special tools and equipment
4. Service user coordination
5. Equipment availability
6. Service user notification – examples
7. Automotive notification – examples
8. Control reporting
9. What should be included
10. Schedule for supervisor
11. Schedule for supervisor service user
12. Overdue for maintenance and service user
13. Missed PM report for maintenance and service user
14. Complete PM’s
15. Summary report of all PM’s completed
16. Listing of all PM’s set-up in program
17. Planning and scheduling index example
18. Assurance of work performed
19. Conformance and auditing
20. Feedback evaluation/corrective action cycle

5.  EXAMINING RESULTS

1. Effectiveness of the preventive maintenance program
2. Refining the PM program
3. 3Correlating preventive maintenance to breakdown maintenance
4. Measuring and appraising the PM program
5. Equipment history
6. Analyzing equipment failures
7. Some relevant maintenance control indices

6. APPLICATION EXERCISE

1. How to organize, develop and implement a successful preventive maintenance program summary
2. Adapting the PM concept at your location
3. Hands-on exercise

INSTRUCTUR

DR. IR. Tri Yuswijayanto Zaenuri and Team

PRICE

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