Preventive and Predictive Maintenance

OBJECTIVE Preventive and predictive maintenance is a maintenance system which very reliable to prevent some sudden troubles or breakdown that may happened on factory’s tools/equipments. The sudden troubles are very potential things that caused a big loss in production process. The effects of this problem are some failure to achieve production target, the lack of personnel, unprepared spare parts, etc. Preventive and predictive maintenance application system starts from standard arranging, activity planning, realization supervising, and, as the finish line is, evaluating and analyzing the maintenance’s result. BENEFIT After completing this course, participants will be able to:

• Develop, implement and supervise the preventive and predictive maintenance program
• Economize the time, money and company’s resources by using sophisticated technique and method in order to optimize the affectivity of maintenance
• Prevent the company’s equipment and tools from damage and make the machine’s living period longer
• Decrease the down time
• Increase the profit

COURSE CONTENT 1. Why Preventive and Predictive Maintenance

• Apprising Maintenance Performance and Effectiveness
• Typical Maintenance Controls
• Reactive Maintenance
• Anticipative Maintenance
• Ascertainment of Equipment Condition
• The Need for Preventive Maintenance
• Why Preventive Maintenance
• Preventive Predictive Maintenance Objectives
• Preventive Predictive Maintenance Prerequisites
• Preventive Maintenance Feasibility Analysis
• Policies
• PM Program Functions
• Cost Impact
• Saving Potential

2. Developing the Preventive Predictive Maintenance Program

• Assignment of Organizational Responsibilities Typical Maintenance Functional Assignments Operational Concepts
• Equipment to be Included
• Equipment Inventory Sheet Examples
• Equipment Numbering Concepts
• The PM Work Order
• Developing the Inspection Sheet
• ECS Rating Sheet as Cross Reference
• Sample of Equipment Components
• Spare Parts and Material Needs
• Inspection Sheet Examples
• Determining the Frequency Cycle
• Frequency Cycle Examples
• Scheduled Frequency Overview
• Developing Job Safety Practices Typical Examples
• Considering Manual Versus Computerization
• Predictive Maintenance can Determine Maintenance Requirement
• Predictive Maintenance and its Applied Techniques as part of the PM Program
• Vibration Analysis
• Wear Particle Analyzing
• Thermography

3. Implementation of Preventive Maintenance Program

• Job Planning
• The Planning Function
• Planning, Service To Do
• Job Planning Prerequisite
• Planners Qualifications
• Duties and Responsibilities of Planners
• The Hob Package
• Line Supervisors Qualifications
• Planning Permits Us, to Forecast, Communicate and Measure
• What Job Should be Planned
• Time Required to Perform Work Labor Content
• Standard Defined
• Consistency of Estimating
• Estimating Methods
• Work Backlog
• Scheduling of Maintenance Work
• PERT and CPM as Scheduling Tools
• Loading of the PM Work Order
• Load Leveling
• Weekly Scheduling
• Manpower Requirements Forecasting
• Forecasting by Crew
• Forecasting by Department
• Weekly Schedule Computer and Manual Example
• Training of Personnel

4. Controlling the Preventive Predictive Maintenance Process

• Preventive Maintenance Administration
• Planned Maintenance
• Special Tools and Equipment
• Service User Coordination
• Equipment Availability
• Service User Notification Examples
• Automotive Notification Examples
• Control Reporting
• What should be Included
• Schedule for Supervisor
• Schedule for Supervisor Service User
• Overdue for Maintenance and Service User
• Missed PM Report for Maintenance and Service User
• Complete PM’s
• Summary Report of all PM’s Completed
• Listing of all PM’s set-up in Program
• Planning and Scheduling Index Example
• Assurance of Work Performed
• Conformance and Auditing
• Feedback Evaluation/Corrective Action Cycle

5. Examining Results

• Effectiveness of the Preventive Maintenance Program
• Refining the PM Program
• 3 Correlating Preventive Maintenance to Breakdown Maintenance
• Measuring and Appraising the PM Program
• Equipment History
• Analyzing Equipment Failures
• Some Relevant Maintenance Control Indices

6. Application Exercise

• How to Organize, Develop and Implement a Successful Preventive Maintenance Program Summary
• Adapting the PM Concept at Your Location
• Hands-on Exercise

7. Piping

• Dasar-dasar dari Sistem Perawatan
• Perakitan dan Pembongkaran dalam Perawatan
• Pengukuran dan Penyimpanan
• Kegagalan dan Kerusakan
• Jenis Perakitan

8. Pumps

• The Need to Identify Critical Equipment
• Check Sheets
• Predictive Maintenance Tools (Vibration Measurement, Oil Analysis, Infrared, and Ultrasound)
• Pressure Testing
• Dead Heading
• Flow Testing
• Pump Purchases & Acceptance
• Advantages of Computer-Based Maintenance Management Software (CMMS)

PARTICIPANT This special course is designed for manager, supervisor, engineer, planer, foreman, and technician. Also, for those who are in operations, engineering and purchasing division and who would like to acquire an understanding of how the quality of the maintenance function affects their function.   TRAINING METHOD Presentation Discussion Case Study Evaluation FACILITIES Training Kit Handout Certificate Lunch + 2x Coffee Break Souvenir Pick Up Participant (Yogyakarta) PELATIHAN LAINNYA