Simple Solutions That Work! Issue 10

BACK-2-BASICS the transition from the “break- down repair squad” philosophy to true preventive maintenance thinking, disillusionment since positive results are not immedi- ately evident. Assemble your team, establish goals and metrics, create a fund- ing resource, and meet routinely to review and discuss results. Only after routine conversation will you be able to reinforce the importance of a robust preventa- tive maintenance program. After committing to the plan, your next step should be to com- pile a list of production machines and equipment directly involved in the manufacturing process. That equipment list should be grouped according to their importance to the production process. I. Indispensable machines are defined as those whose break- down would interrupt one or more steps in the entire produc- tion process and for which no standby unit exists, or whose function cannot be performed temporarily by alternative means. The single cupola of a small foundry is an example. II. Marginal equipment contrib- utes indirectly to the production process but its breakdown would not be a major inconvenience. The foundry clean-up truck is an example. This method of classifying ma- chines is similar to the process used in network analysis to de- termine (critical) and (non-criti- cal) activities. After every piece of equipment has been given a maintenance priority rating, it is possible to establish an appropriate preven- tive maintenance program which will maintain each item in the condition appropriate to its rat- ing. The frequency and care with which each machine is serviced are determined by factors spe- cific to that machine in its partic- ular environment. It is therefore not feasible to describe valid preventive main- tenance procedures to cover all possible situations; however, cer- tain guidelines can be set forth which will help to determine those components of machines and equipment, which should receive primary attention. The equipment components, 4527 HOW TO Continued on next page which should be located and clearly identified when setting up a preventive maintenance program include: A. All lubrication points B. All electric motors or driving mechanisms C. All electrical control equipment D. All hydraulic and pneumatic components E. All mechanical parts of assem- blies subject to appreciable wear This survey should not be based solely on manufacturer’s drawings. Identify each element by actually inspecting the equipment con- cerned and then mark these in on suitable plant layout drawings. After the above steps are com- pleted, then define the plant areas that need to receive some form of preventive maintenance – so that specific preventive maintenance work schedules can be estab- lished. SETTING UP A LUBRICATION PROGRAM The lubrication program can be developed in a straightforward manner by following the simple steps described below: I. Standardize and code lubri- cants – From equipment manufac- turer’s service manuals and data from lubricant suppliers establish a minimum number of standard lu- bricants which will cover all equip- ment needs. II. Set up a central storage area for all lubricants – Ensure that lubricants are stored in such a manner that sand or other impu- rities cannot contaminate them.