Development, Validation, Implementation and Enhancement of a

Voluntary Protection Programs Center of Excellence (VPP CX)

Capability for Department of Defense (DoD)

Preventive Maintenance
Department of Defense
Voluntary Protection Programs
DoD Lead Agent: Center of Excellence
Office of the Assistant
Operated by:
Secretary of the Army
(Installations and
Environment)
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 Objectives

After this training you will be able to:

• Define a Preventive Maintenance (PM) system
• Recognize reasons and need for a PM system
• Define advantages of a PM system
• Recognize risks of a PM system
• State the law of PM
• Describe the PM execution process
• Describe ways to fix data absence
• Define ways to motivate PM workers.

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 What is Preventive Maintenance?

• 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.
• Designed to:
– Preserve and enhance equipment reliability
by replacing worn components
– Ensure machine failures are not the cause for
workplace mishaps.

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 VPP Requirements for
Preventive Maintenance
• A written preventive and predictive maintenance system
must be in place
– VPP Federal Register Notice 65:45649-45663, 7/24/2000
• Equipment must be replaced or repaired on a schedule,
following manufacturers’ recommendations
• Documented records of maintenance and repairs must be
kept
• The system must include maintenance of hazard controls
such as machine guards, exhaust ventilation, mufflers,
control circuits and devices, etc.

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 Need for PM System

• A PM system aligns with a safety

management program to:
– Prevent injuries caused by
malfunctioning equipment
– Increase automation
– Reduce losses due to production
delays
– Improve quality
– Just-in-time manufacturing
– Provides a more organized work
environment.

Image courtesy of www.defenselink.mil

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 Advantages of a PM System

• Some advantages of a PM system include:

– Reduced production downtime
– Conservation of assets and increased life
expectancy of assets (both machine and human)
– Ensuring all equipment safety features are
functioning properly
– Reduced cost of repairs by reducing secondary failures
– Quality products
– Identification of equipment with excessive maintenance costs
– Improved safety and quality conditions.

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 Errors of a PM System

• PM system errors could

include:
– Damage to an adjacent
equipment
during a PM task
– Damage due to an error in
reinstalling equipment into its
original location
– Damage due to the installation of
new parts.

Image courtesy of www.defenselink.mil

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 The Law of PM Programs

The higher the value of plant assets and

equipment per square foot of facility, the
greater will be the return.

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 Things To Consider

• Things to consider after completing a maintenance

operations:
– Ensure equipment meets manufacturer’s specification
– Review job hazard analysis (JHA) to ensure equipment
alterations or equipment maintenance did not introduce
new hazards not included on the JHA
– Conduct machine checks to ensure all feature, especially
safety devices, are functioning properly
– Ensure employees are aware of any changes to
equipment and/or operating procedures.

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 A Successful PM System

• Three keys for a successful

PM system:
– Scheduling: Should be
automated to the maximum
extent possible
– Execution: Should be done
before an actual break down
occurs
– Quality: Should have a formal
process for checking the
quality of repairs.

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 PM Focus

• PM focus should be on:

– Cleaning
– Lubrication and inspection
– Correcting deficiencies
– Operation of safety devices.

• Pre-determined parts replacement

should be minimal and done only
where evidence clearly indicates
wear-out characteristics.
Image courtesy of www.defenselink.mil

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 Data Absence

• When data on PM is absence

some techniques which can be
used to assist in its creation are:
– Structural/facility
– Age exploration programs
– Statistical analysis
– Safety inspection data.

• Cost should not be a primary

factor in deciding against data
collection for a PM system.
Image courtesy of www.defenselink.mil

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 Preventive Maintenance Workers

• Ways to motivate your PM workers include:

– Establishing effective training programs
– Establishing inspection and preventive maintenance as a recognized,
important part of the overall maintenance program, including follow-ups
– Assigning competent, responsible people to the preventive maintenance
program
– Setting high standards
– Publicizing reduced costs with improved up-time and revenues and
employee safety, which are the result of an effective preventive
maintenance system.

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 Summary

In this presentation you learned about:

• PM
• Reasons for the PM system
• Advantages of a PM system
• Errors of a PM system
• PM after action items
• Successful PM system
• PM focus
• Ways to motivate PM workers.

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 Questions?

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