maintenance procedure steps

How much time do people use doing activities that don’t add any value to the goal of achieving the best results? We must control a hydraulic system by telling it when we will perform maintenance on it and how much money we will spend on the maintenance for the system. Clean the filter cover or housing with a cleaning agent and clean rags. The backlog represents a comprehensive list of all work yet to be completed. Flow and pressure checks: Preferred: Every 2 weeks, Ruisheng Li, in Distributed Power Resources, 2019. Table 11–1. Planning – The first step in any road construction and maintenance project is properly planning and evaluating the needs it is intended to serve. Check Fluid Levels (Step 11) Add Tip Ask Question Comment Download. The development of any program must take into consideration the maintenance tasks that need be carried out and the resources available, thereby ensuring that product quality and personnel safety standards are met. Covering responsibilities and step wise guides including pictures as applicable. Some detectors require stabilization time after maintenance before calibration can be performed. However, by using these eight important elements, you can build an effective blueprint for success. Based on historical trending of oil samples. Seán Moran, in An Applied Guide to Process and Plant Design (Second Edition), 2019. Simple checks would be reviewing the service history, noise and vibration inspections. Example of preventive maintenance task description. Although these rather broad definitions leave their actual meanings open to interpretation, they do indicate the broader view of maintenance it is necessary to take to create a robust strategy. Let the equipment fail and then fix it (corrective or “run to failure” maintenance). Figure 58.5 shows a belt gage, an alternate means of determining belt wear, which measures belt total width (TW). It uses the ideas of FMECA to identify failure modes, and the principles and concepts of preventive maintenance to identify the effective maintenance tasks. Recognise that although the technician and reliability engineer are on the front line of equipment maintenance, a much wider team of people are involved in determining the success of the maintenance operation. A good maintenance operation commonly uses measures such as overall equipment effectiveness and service level. 3T maintenance procedure below and consider what an ACE maintenance SOP format with 3T content can do for maintenance work quality and resulting reliability of your plant and equipment. … Pulleys should be inspected prior to replacing belts to ensure they are in good operating condition. Return filter: Typically has a bypass, which will allow contaminated oil to bypass the filter before indicating the filter needs to be changed. If the planned maintenance program is prepared without due consideration of the demands placed on the operation element, the program would probably collapse when the plant's equipment could not be released (i.e. Priority should be given to amending and updating procedures in a timely manner. In order to obtain an overall assessment of maintenance requirements in an organization, a “walk through” review of all areas with medical devices is beneficial. Such a case may be where the spare part, or indeed the equipment itself, can be replaced very cheaply, or where the operation can function adequately for a while without the use of the asset. At item level the TDBUA as far as possible uses concepts, principles and experience to decide on the maintenance procedures (tasks) and reserves a FMECA for only the most complex of items. The maintenance manager will be only too familiar with the increasing need to maintain equipment in a cost-effective manner. In this article, we’ll define seven steps that will underpin a winning maintenance strategy. An existing SOP may need to just be modified and updated, or you may be in a scenario where you have to write one from scratch. The maintenance operation will always achieve the results that it is designed for. Many maintenance management software options allow you to print bar codes right in the system, making this step relatively painless. A robust maintenance strategy creates a focus for the maintenance operation and creates a consistent ambition for the maintenance team, aligned to the needs of the parent organisation. The TDBUA is business centered and via Step 1 brings down business-centered objectives to the preventive maintenance decision-making of Step 2. The overall scope necessary for adequate plant maintenance procedures and services is highlighted in the charts shown in Section II and Section III. A Standard Operating Procedure (SOP) is a document consisting of step-by-step information on how to execute a task. Clean the inside of a hydraulic reservoir. Human factors and ‘As Low As Reasonably Achievable’ (ALARA) principles should be considered in the preparation of maintenance instructions. Although the reliability and safety requirements of the organisation’s assets should be at the core, a robust strategy also defines what capabilities the maintenance team needs, and aligns all the efforts of the equipment designers, users and maintainers towards a proactive maintenance culture. Preventive maintenance procedures must be a part of the PM Job Plan, which includes the following: Tools or special equipment required to perform the task, Parts or material required to perform the procedure with storeroom number, Environmental concerns or potential hazards. P-80 Lubricants are the “Product of Choice” for Pump, Hose & Seal Maintenance, Repair and Assembly. Basic Services Performed: 1. CAUTION: NEVER allow your hand to touch a filter cartridge. You will discover the power of an ACE 3T maintenance procedure as you read the following example maintenance SOP. For example, an 8V belt should measure 88" (i.e., 1 inch), a 5V belt should measure ⅝", and a 3V belt should measure ⅜". There is a vital cultural element to any type of improvement activity and ignoring it can often be the reason improvement initiatives unexplainedly fail. Each party will get a chance to explain why he/she requires maintenance and also why he/she can’t afford the maintenance requested. Then, as the realisation sets in that this will take the organisation only so far in downtime reduction and efficient resource allocation, more planned activities take place, with the emphasis more on job and workforce planning but still dealing with breakdowns in a rather reactive way. Check and record vacuum on the suction side of the pump. Most of the specialist consultancies also have structured frameworks which can be assessed against, at a cost. What are the real, underlying or root causes for failure? Check for excessive fluctuation of the hydraulic system (designate the fluctuation allowed). Tunbridge Wells These procedures are Word format and you need to add company logo, document number and revision number etc. Step 1: Turn the machine off from the main power point and fit your tag??? These are key management ratios at the heart of every business and should be used as the basis for justifying any maintenance programme changes. As individuals in the organisation learn to do a wider range of things, better results should follow. Overdue PM tasks in the backlog highlight problems in your work processes. The Bretby index could use an addendum by means of which maintenance issues can be managed as well as designed (because maintenance is as much a management issue as a design issue). Systems can range from the complete maintenance of plant and equipment using all available methods to their replacement on failure. Many companies have tried to improve the efficiency of maintenance in their plants. Clean the insides of the reservoir by opening the reservoir and cleaning the reservoir with a lint-free rag. Complex maintenance and calibration procedures usually require skilled personnel commanding higher labor charges. Figure 58.3. After completion of repair, the O&M personnel will accurately report the type of device fault and the repair time to the cloud O&M center. The cloud O&M center sends the fault warning (or the repair warning information) and the position of the fault device to the O&M personnel. To meet the company's requirements it is then necessary to decide on the maintenance system that provides the most satisfactory benefits overall. There are some easy-to-grasp elements, however: The maintenance maturity of an operation and its culture are directly linked, simply because it is not normally possible to develop the range of capabilities necessary to be a high performing maintenance operation without the supporting cultural focus, rewards and recognition. It will be noticed that Step 2 of the TDBUA is much more pragmatic than RCM in that it ranks units in order of importance and concentrates the analytical resources on the most critical units. Therefore, the end user must rely on the manuals provided by each of the component manufacturers. vibration, temperatures, current, etc. (See Chapter 36). As in all preventive maintenance programs, we must write procedures required for each PM task. In doing so, capacity and capability will increase, and the ability to adapt to changing conditions will improve. Best practices are defined as professional practices that are prescribed as being correct or most effective. Preventive maintenance is work to be carried out at a specific frequency as indicated by potential failures or known reduction in efficiency of the plant and equipment, thereby avoiding failures or a decrease in performance. Afterwards, spray clean hydraulic fluid into the reservoir and drain out of the system. Each and every facility is different, with different goals, assets and resources. Remove the old filter with clean hands and install new filter into the filter housing or screw into place. Paul C. Manz, in Semiconductor Safety Handbook, 1998. Similarly, efficient maintenance labour planning can lead to a lower requirement for manpower, and therefore reduce the business’s cost of goods sold (COGS). Operation must play an important part in the programming. Which scenario you can perform depends on the product version which you specify when you create the maintenance procedure. James McCauley, in Clinical Engineering Handbook, 2004. Selecting the right approach to each asset’s maintenance regime is therefore fundamental. 3- Brazing Procedure Using Oxy-Acetylene Brazing Set. Fig. Never reinstall damaged or worn pulleys on equipment; it is important to always repair or replace them. It cannot be flexibly modified to include smaller machines or consumer products. It is useful to consider maintenance strategy from a dual perspective: This model puts, quite properly, the asset at the heart of the maintenance strategy – defining what is needed to achieve its optimum performance; and then around it is defined all the management tasks needed to provide the asset care strategy at the core. It follows that operational demands, whether they be from a service utility installation, a production line, a mainframe computer or an office environment, will play a major part in reaching the decision as to what type of maintenance program requires implementation. , to avoid someone can try to use the … Out of Order??? The required level of skill and methods of procedure use should be stated. In this step, the existing situation is analyzed to establish baseline values and targets for the Quality Maintenance project and plan for its smooth implementation. Understanding the inputs – Where does the money go? Condition monitoring, life cycle costing and predictive maintenance procedures should all be considered during the preparation of the planned maintenance system. In order to validate your preventive maintenance procedures, you must have a good understanding and knowledge of Best Maintenance Practices for hydraulic systems. If the assessment result is smaller than the eligible value, the cloud O&M center will send the type and probability of the possible fault and the geographic position of the device to the O&M personnel, so as to repair the device in advance (see Fig. When strategy, capability and culture come together the results can be a proactive maintenance operation that provides strategic advantage in the marketplace and adds real financial value to the parent organisation. The system has been opened for major work. Since maintenance and calibration procedures are usually performed concurrently by the same individual, increased labor costs can be incurred due to this additional waiting time. Adaptability introduced in this way, in essence, would enhance its universal appeal. Once the main sub-functions themselves are defined, the current level of capability in each of the areas can be assessed by looking at best practices that would be expected to be seen in use to accomplish these tasks. Site security: control of ignition sources brought onto site. Equipment availability can be translated directly into the key objectives for the business. The typical screen breather should not be used in a contaminated environment. Reliable differential pressure measurement. Replace or recondition parts at intervals known to approximate the lifespan of failing components (planned preventive maintenance). This is satisfactory when considering small, less expensive units, which are installed to ensure that the services they are providing are not disrupted (this could also include auxiliary items on major plant and equipment). However, before conducting any inspection or maintenance, always determine, understand, and follow all plant safety rules. Check hydraulic hoses, tubing, and fittings. A thorough inspection of the belt-drive system components (i.e., belt and pulleys) should be performed prior to installing new or replacement belts and pulleys. The procedures should normally be prepared in cooperation with the designers, the suppliers of plant and equipment, and the personnel conducting activities for quality assurance, radiation protection and technical support. Steps or procedures must be written for each task, and they must be accurate and understandable by all maintenance personnel from entry-level to master. If no reliable maintenance history is available, then inspection and condition monitoring, or testing, can help to establish the status of a device. Maximize component and life and reduce the need for repairs using a broad capability model where. The following example maintenance SOP technically accurate, properly verified, validated, authorized and periodically.... Ii and Section III panic that there server has crashed into pragmatic steps calibration! Of CCTV maintenance and why it’s essential for your business a maintenance operation always... 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