Implementing Preventive Maintenance/Predictive Maintenance

Each year, industry in the United States spends over $700 billion on plant equipment maintenance.

According to maintenance specialists, at least 40% of that is wasted. And that’s just the tip of the iceberg. Bad maintenance is responsible for equipment failures, disrupted production schedules, delays in deliveries, and poor product quality. Why is industry wasting 2 out of every 3 dollars spent on maintenance? The answer is simple—poor management and poor systems.

Preventive and Predictive maintenance techniques provide data that defines servicing and inspection periods so that maintenance departments can determine, in advance, when equipment should be shut down for overhaul. Statistics are proving that these programs, properly implemented, can minimize equipment and system breakdowns,resulting in a major reduction in total maintenance and operation costs. This seminar will teach you everything you need to understand and implement these money-saving techniques.

Expand Your Knowledge

• Key steps for launching a PPM system
• Getting your equipment under control
• What to inspect, what not to inspect
• Methods of maintaining a PPM program

Gain Key Skills and Insights

• The defect type that causes 90% of all breakdowns(it's not what you might have thought)
• The 12 step process to implement a Preventive/Predictive Maintenance Program
• How to apply cost avoidance to win credibility
• How to apply root cause analysis to proactive maintenance strategies
• How to identify targets for PPM applications - where to begin
• How to logically link PdM to your PM system
• How to select the right equipment
• How to establish an effective lubrication program that will increase reliability and save money

• The importance of physical asset management
• The nature of failures, failure classifications, failure patterns, and how to use this information to create maintenance strategies that impact the bottom line
• The differences among the various maintenance methods and the appropriate application of each
• The benefits and cost-effectiveness of implementing an effective PPM program
• Guidelines for developing a World Class PPM program by using a 12-step process
• Advanced Preventive/Predictive Maintenance strategies
• Techniques to ensure your PPM program impacts equipment reliability

Those responsible for, involved with or impacted by:

• Building a preventive/predictive maintenance program
• Creating new PMs or rewriting current PMs
• Determining the best techniques to use for certain PMs
• Purchasing PM/PdM equipment or service

Introduction to World Class PPM

Importance of Physical Asset Management

Nature of Failures

Understand the Nature of Failures
Failure Classifications and Failure Patterns

Maintenance Methods Compared

Breakdown Maintenance

Preventive Maintenance-Lubrication

Cost of Poor Lubrication
Fundamentals-Oil & Grease
Storage & Handling Methods
Oil Analysis
Organization
Comparative Viscosity
Classifications

Preventive Maintenance (time-based/dynamic-based)

General Philosophy
Upside
Downside
CLAIR Activities

Predictive Maintenance (condition-based)

Monitoring Techniques
Twelve Essential Steps in building a PdM Program

Proactive Maintenance

Life Cycle Costing
Maintenance Prevention Design
Purchase Specifications
Acceptance Testing
Root Cause Failure Analysis (RCFA)
Additional Maintenance Practices

Benefits & Economics of PPM

Increase Equipment Up time
Improve Product Quality
Cut Inventory Cost
Improve Labor Productivity
How to Reach Lowest Total Cost Through PPM
Payback

Putting it All Together-Roadmap to a World Class PPM Program

Writing Tasks and Procedures
Developing Equipment Manuals
Scheduling PPM Tasks
Quality Assurance & Continuous Improvement
Measuring the Results
Role of the Maintenance Organization
Implementation-12 Steps to Developing a PPM Program

Advanced Strategies

Reliability Centered Maintenance
PM Optimization
TPM
Statistical Analysis

	Mark Pond As a long-time employee of Leggett & Platt, Mark Pond has demonstrated his expertise in managing all aspects of facilities maintenance. As Maintenance Manager, Mark has been responsible for facilitating and overseeing machine maintenance, material handling equipment, energy conservation and implementation of a TPM (Total Productive Manufacturing) program. Mark has proven himself as an exemplary leader, not afraid to roll up his sleeves to coach and lead a staff of 20 maintenance workers including Journeyman Machinists to... Read More
	Hank Bardel Mr. Bardel is a maintenance consultant whose thirty plus years in the maintenance field includes a broad range of experience from entry-level electrical technician to maintenance supervision and management. Most recently, Hank served as a TPM Coordinator, where he trained and instituted Equipment Improvement Teams and trained approximately 70 shift crews on the 5S process. Mr. Bardel’s work experience includes an eight-year stint in the United States Air Force, where he gained much experience in electronics, general...Read More
	Glenn Smith Glenn Smith is an experienced maintenance and manufacturing engineer with over thirty-seven years of experience in engineering maintenance, electrical/instrument field, maintenance supervision, safety management and area operations. As maintenance supervisor for E.I. Dupont, Glenn was responsible for developing and implementing preventive/predictive maintenance schedules and developing planning/scheduling metrics and cost metrics. Mr. Smith had supervisory responsibilities over approximately 36 employees, as well as managing a $3 million budget. Having served as a planner/scheduler for over eight years, Glenn is able to cover the "nuts and bolts" of P&S in an easy to understand, step-by-step manner... Read More
	Shane Bradley Shane Bradley is an experienced Electrical Engineer with specialization in the field of process systems. He is knowledgeable and fluent in programmable controller logic, networking, data communications, computer languages and other P.C. based logic control systems. He has six years of experience at a major electronics firm as an industrial control specialist supporting process controllers. For three years, he served as Vice-President of Engineering for a systems integrator specializing in building automation, including monitoring and... Read More
	Tracy Strawn Mr. Strawn is a Maintenance and Reliability Consultant with over thirty years experience in the process and manufacturing industries with most of that time spent in the upstream oil and gas industry managing surface and subsurface activities. His experience encompasses maintenance and repair on production and manufacturing equipment including rotating equipment, tanks, vessels, pipelines, instrumentation and controls and high voltage power systems. He has designed and implemented a number of maintenance and reliability...Read More

On-site Training

Are you looking for customized training delivered at your facility?

Are you looking for effective group training?

Do you want training specific to your facility, systems and equipment?

If so, our on-ite training is for you. This cost-effective training method also reduces travel and accommodation expenses. Call Glenna today at 1-800-637-0120 to learn how you and benefit and save from on-site training.