Preventive Maintenance Program

• Preventive maintenance is a schedule of planned maintenance

actions aimed at the prevention of breakdowns and failures.
• The primary goal of preventive maintenance is to prevent the failure
of equipment before it actually occurs. It is designed to preserve and
enhance equipment reliability by replacing worn components before
they actually fail.
• The process includes planned inspections of the organization’s assets
and scheduling for their replacement or service.
Preventive Maintenance Principle:
• Prevention is better than cure
• Aims at minimising the problems of breakdown maintenance
• Locates Weak Spots
• Provides Regular inspection
• Initiates minor repairs thereby reducing the risk of unanticipated
breakdown
Objectives
Minimizing the possibility of unanticipated
production interruption.

Reduce work content of maintenance

jobs.
Maintain optimum productive
efficiency of the equipment.
Make plant equipment and machinery
always available and ready for use.

Ensure safety of life of the workmen

achieve maximum production at

minimum repair cost.

Maintain operational accuracy.

Four common types of preventive
maintenance (PM) include:
• A recurring work order is scheduled for when a specified time interval is
Calendar-based maintenance reached in the computerized maintenance management system (CMMS)

• Meter readings are used and logged in the CMMS. When a specific unit is
Usage-based maintenance reached, a work order is created for routine maintenance.

• When work order data is logged in the CMMS, maintenance managers can
Predictive maintenance predict when an asset will crash based on historical events and create specific
PMs to prevent them from happening again

•This
Prescriptive maintenance
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Prevention maintenance: phases and roles
Elements/Procedure of PM :
Who should do PM?

Where to start PM?

What to inspect in PM?

How often to inspect ?

When to inspect- schedules ?

Preventive maintenance records

Control and evaluation of PM

Who should do PM?

A separate division
Production Maintenance
of inspectors and
department. department.
supervisors
Where to start PM?

It is better to
PM should tackle one
not be done department
for the entire or machinery
plant at once at a time

The entire PM
programme hangs
on inspections and
their related duties
of adjustments and
repairs
What to inspect in PM?
• All industries have certain key items which are more essential for
continuing the production than others.
Process
equipment

Special purpose – Safety

unique equipment
and machines equipment
key items
are :

Water , air Material

handling
and fuel lines equipment
What to inspect for ?
• After listing the equipment requiring PM , the next step is to decide – what
physical parts of each piece of equipment need attention
• After making the list of machines and their parts needing PM , a CHECK –
LIST to ensure that no inspection point has been missed is made

How often to inspect ?

Based on :
 Past experience
 Cost and savings
Over inspection Expensive
Under inspection More breakdown
When to inspect- schedules ?
• Scheduling involves determining calendar inspection dates that will
fulfil the frequency requirements in the most efficient way.
• In setting up schedule one must ensure to keep production going at
lowest overall cost.
• Schedules should be set in consultation with production department
and as per the production needs , as far as possible.
Preventive maintenance records
Record should show
Type of equipment and description

Whether it is a key item?

Name of the manufacturer

Cost and date of purchase of the
equipment.
Location of the equipment in the
factory
Equipment identification number
Estimated cost of inspection and the
cost and data of planned repairs
Breakdowns , their dates and reasons
Cost of breakdowns and other
associated implications
Control and evaluation of PM :

To maintain
Periodic review
control of the PM
of PM
programme , the
programme with
following
the operating
measures should
department
be taken :

Analytical Review of monthly

approach to the reports of PM
evaluation of PM inspections
Analytical approach makes use of following
relations :
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• ×100 = 10% Max
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‫݁݇ݎ݋ݓ ݏݎݑ݋ܪ‬
• ×100 = Percentage of performance
ܶ‫ ݈ܽݐ݋‬h‫݀݁݇ݎ݋ݓ ݏݎݑ݋‬
Advantages of PM System
Reduced production • resulting in fewer machine breakdowns
downtime • Through proper maintenance of equipments

Better conservation of • eliminating premature replacement of machinery and

and increased life equipment
expectancy of assets • When equipment is properly maintained it would increase
and maintain the life expectancy of a certain asset

• routine checks and repairs would be less expensive

Timely routine repairs than large scale repairs which would require intensive
repairs causing longer system break-downs
Advantages -Continued
Reduced cost of repairs
• When parts fail in service they usually
by reducing secondary
failures damage other parts

• Reduce product rejects, rework and

Better quality Products
and Improved safety and
scrap due to better equipment
condition

Identification of
equipment with excessive • Corrective maintenance techniques
maintenance costs • Operator training
Potential Risks of PM
Damage Due to Error
Damage to Adjacent Reintroducing Infant
in Reinstalling
Equipments Mortality
Equipments
• damage that might • Every time new • Sometimes pieces
occur to the parts are being are taken apart and
adjacent installed, the cannot be put back
equipment that is equipment goes to their original form
around the through the infant
equipment that is stage where it will
being maintained. either fail or
These kind of succeed. This
errors might occur uncertainty of the
due to accidents new part of working
such as oil leaks, properly is referred
re-connection to as the infant
errors and etc. morality
The key to Successful PM System

Scheduling Should be automated

Executing
to the maximum Should be done
extent possible before the actual
Work is completed breakdown occurs
according to schedule

Improper scheduling
leads to inefficient Improper execution,
PM and increased failed PM
cost
 Example of PM procedure
Rotary Tablet Press Machine Preventive Maintenance Procedure

Purpose: To establish a standard preventive maintenance procedure of

Rotary Tablet Press machine
Scope: To ensure safe and standard preventive maintenance procedure
of Rotary Tablet Press machine to meet the required smooth operation in
solid & liquid production area.
Responsibility: Engineering Personnel
Abbreviations and Definitions: Rotary Screen Printing mc
Health and Safety Considerations: None

Reference Document
•Working experience
•Annexes
•Maintenance Chart.
Procedure
•Inspection for voltage fluctuation
•Proper earthing condition of machine
•Inspection the supply pressure must be 5-6 bar.
•Check the any leakage of compressed air
•Check the free movement of turret
•Abnormal sound & any physical damage of turret
•Abnormal sound of motor
•Driving belt
•Any physical damage of motor pulley & driving pulley
•Motor bearing.
•Correct function of pulley
•Spring tension of variable speed pulley
•Any physical damage of total assembly upper & lower cam track assembly
•Correct function of weight box
•Correct penetration function
•Any physical damage of upper press roll
•Any physical damage of pressure roll & pin of overload pressure release assembly
•Any physical damage pressure adjustment hand wheel of overload pressure release assembly
•Tension of compression spring
•Check any damage of lubricating pipe
•Proper function of lubricating hand pump
•Correct function of proximity/sensor/safety switch
•Any physical damage of proximity/sensor/safety switch
•Correct function of all pneumatic components
•Any leakage of air, cleaning or change if required.
•Greased all greasing point (By grease)
•Change Gear oil in gear box
•After completion of maintenance record as per SOP