Understanding Maintenance Plans | Quality Digest

Step 2: Perform a criticality assessment

Published June 12, 2024, by Limble.

منبع: https://www.qualitydigest.com/inside/risk-management-article/understanding-maintenance-plans-070824.html

Identify the systems, equipment, and machinery that should take the highest priority in your maintenance plan based on their criticality to your operation.

Step 1: Conduct an asset inventory

Determine the frequency with which tasks should be performed based on intervals (daily, weekly, monthly), use (units produced, hours of operations), or according to operating conditions (climate, natural elements).

The following are key components of an effective maintenance schedule:

Step 4: Identify essential maintenance tasks

Together, these details provide a structured approach to your operation’s maintenance activities. This approach can ultimately improve resource allocation and help you better anticipate downtime-causing events.

Key components of a maintenance plan

Your industry, the size of your operation, and the availability of resources, including capital and maintenance personnel, will shape your maintenance plan. Naturally, the type of equipment your organization uses will also play a role. There is, however, a standard set of features common to most successful maintenance plans. An effective maintenance plan will typically include the following key components:

Step 6: Allocate resources for your maintenance tasks

Step 3: Define your key performance indicators (KPIs)

Compile a comprehensive list of the tools, materials, parts, and personnel required to carry out each maintenance task, as well as details on roles and responsibilities.

Maintenance plans

Step 9: Create a maintenance schedule

Maintenance plans and maintenance schedules are two closely related concepts, but there are a few important distinctions.

Together, these benefits provide a structured remedy to common maintenance challenges such as unexpected equipment failure, maintenance task backlogs, inventory stockouts, and overburdened maintenance teams.

Ten steps for creating and implementing a maintenance plan

Timeline specifying when each maintenance task should be performed
Metrics for determining the frequency of maintenance tasks such as intervals (weekly, seasonally, annually) or use (hours of operation, units produced, etc.)
Task delegation, assigning maintenance technicians and teams to particular tasks
Resource allocation, identifying the tools, materials, and spare parts needed to complete each task
Safety requirements and compliance standards applying to the performance and documentation of each task

Why are maintenance plans important?

Whereas a maintenance plan provides a comprehensive framework for implementing a preventive maintenance program, the maintenance schedule is a critical tool for carrying this plan out. Because your maintenance schedule is a part of your broader maintenance plan, you will note some overlap between the components of each.

Implement an advanced asset management software solution to manage work orders, track maintenance activities, schedule tasks, document completed work, produce data insights and reporting, and monitor equipment performance.

Automating maintenance planning and scheduling

Step 5: Establish metrics for task scheduling

Many of the steps required to implement an effective maintenance plan can be simplified and automated with the help of an advanced maintenance software solution. Limble provides a user-friendly platform that includes:
Centralized information management
Automated preventive maintenance scheduling
Streamlined work order management
Real-time inventory tracking
Getting ahead with predictive maintenance
Mobile app
Advanced data analysis and reporting
Seamless integration with existing management systems

A CMMS platform can help you implement an effective maintenance plan, transition to a more effective preventive maintenance strategy, and ultimately drive your business to new heights of productivity and profitability.

A maintenance plan is a detailed document or set of documents that outlines the specific maintenance tasks required to keep your equipment, machinery, and systems operating efficiently and effectively. This plan will typically include a timeline for scheduled maintenance tasks; details on how to complete these tasks; specifications on the tools, materials, and spare parts required to carry out these procedures; and the assignment of maintenance technicians to specific actions.

Articulate what you plan to achieve with your maintenance plan (e.g., reduced downtime, extended equipment lifespan, improved regulatory compliance) and identify the metrics and benchmarks you’ll use to gauge your success in achieving these objectives.

Step 8: Incorporate compliance and safety standards

As noted above, your maintenance plan will typically include the following:
Asset inventory
Risk assessment
Manufacturer guidelines
Task descriptions
Resource allocation
Task delegation
Safety standards
Documentation requirements
Maintenance schedule

Create a comprehensive list of all maintenance tasks required for the upkeep of each critical asset such as inspections, testing, oil changes, filter changes, and parts replacement. Refer to OEM recommendations and industry best practices for guidance.

Create detailed instructions for the performance and documentation of each maintenance task, and ensure that these instructions are readily accessible to all relevant personnel.

Step 7: Develop SOPs

Thoughtful planning is the cornerstone of an effective preventive maintenance program. Your maintenance plan is the framework for everything from building a maintenance schedule and automating inventory management to streamlining work order management and improving interdepartmental communication and collaboration.

Why is maintenance planning important?

• Comprehensive inventory of physical assets including all equipment, machinery, and systems that require maintenance
Risk assessment including a criticality analysis to help prioritize physical assets, and an evaluation of potential malfunctions and failure modes for high-priority equipment, systems, and subsystems
Manufacturer recommendations for identifying critical tasks, establishing service intervals, and performing repair procedures
Detailed routine maintenance task descriptions outlining the activities required for each asset, such as testing, inspection, cleaning, calibration, and parts replacement
Actionable maintenance schedule indicating when each maintenance task should be performed, as well as the basis for this timeline (e.g., intervals such as weekly, seasonally, annually, or use metrics such as hours of operation or units produced)
Complete lists of the resources required for task completion including tools, raw materials, and spare parts
Delegation of responsibilities, assigning maintenance technicians and teams to specific tasks at designated times
Safety standards including industry best practices, regulatory requirements, and compliance checklists
Documentation requirements, including standard operating procedures (SOPs) for monitoring the condition of equipment, managing work orders, tracking the location of key materials, and recording the completion of tasks

Maintenance plans vs. maintenance schedules

Use existing standards and regulatory requirements to inform all aspects of your plan, including scheduling multipoint inspections of assets and performing routine safety audits.

Step 10: Leverage a computerized maintenance management system

Increased equipment reliability, with regularly scheduled tasks like testing, inspection, and performance monitoring reducing the occurrence of unexpected equipment failures
Extended equipment lifespan, with routine services like calibration, lubrication, and parts replacement reducing the effect of wear and tear, and extending the useful life cycle of critical assets
Cost savings, with preventive maintenance strategies significantly offsetting the higher maintenance costs that come with emergency breakdowns, urgent inventory orders, and premature system replacements
Improved safety conditions, with routine equipment maintenance reducing the likelihood of equipment failure or malfunction, and subsequent accidents, injuries, and compliance failures
Enhanced operational efficiency, with planned maintenance reducing the occurrence of unplanned downtime and maximizing the operational performance of production equipment
Better resource management, with a clear outline of the tools, materials, and parts required for each maintenance task helping to streamline inventory management

Your maintenance plan is a broad framework that outlines the objectives, procedures, and resources required to carry out your organization’s asset management strategy and implement an effective preventive maintenance program. A maintenance plan may also include a long-term strategic outlook for your asset management program.

Maintenance schedules

As the list of components directly above demonstrates, a maintenance schedule is just one of the components that make up a maintenance plan.

Maintenance plans add structure, organization, and efficiency to your maintenance operation. This, in turn, gives your maintenance personnel the data, knowledge, and resources required to be proactive in performing maintenance tasks. Below, we take a closer look at the benefits that come with this proactive approach.

Here’s a simple guide to establishing a preventive maintenance program.

Compile a comprehensive list of equipment and other physical assets requiring maintenance. Log detailed information including the make, model, model year, serial number, warranty details, and location for each asset.

Establish your timeline of maintenance tasks in close coordination with your company’s production schedule and inventory management system to minimize unplanned operational disruption.

That said, effective planning is more than just the key to preventive maintenance. It may be what separates your manufacturing business, auto dealership, or industrial facility from chaos. Unfortunately, far too many businesses employ reactive maintenance programs or run-to-failure asset management strategies simply by default. This is the often-haphazard approach to performing maintenance services. It’s the go-to approach for organizations that don’t plan for regularly scheduled equipment testing, upkeep, and maintenance.

By contrast, effective maintenance planning fosters a more stable, predictable, and cost-effective operational environment. But what is a maintenance plan, exactly? And how can you implement or improve preventive maintenance planning for your organization?

What is a maintenance plan?

In the absence of this proactive planning, your organization risks unplanned equipment breakdowns and failure, prolonged downtime, and in some cases, total operational disruption. These conditions can quickly cascade into missed deadlines, delayed product delivery, lost revenue, and diminished customer satisfaction.