Preventive maintenance
Write, display and keep alive a level 1 and level 2 preventive maintenance schedule on a machine, to replace suffered breakdowns with chosen interventions.
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This course is aimed at team leaders, shop floor managers, methods technicians and maintenance managers who still see their maintenance team acting as firefighters. It assumes no prior knowledge of TPM or of maintenance standards.
By the end, you will be able to distinguish the three forms of preventive maintenance (time-based, condition-based, predictive), rank a machine's functions by criticality, choose operations and their frequencies, build a maintenance schedule that can be displayed at the workstation, then make it last over time: weekly records, handling of reported anomalies, adjustment of frequencies. Each step draws on the same example machine, an injection moulding press, with concrete figures to reproduce on your own line.
What you will be able to do
- Distinguish time-based, condition-based and predictive maintenance, and say which one suits a given component
- Locate maintenance levels 1 and 2 and decide who does what between operator and technician
- Rank a machine's functions by criticality (frequency × severity) based on the manufacturer's documentation and the breakdown history
- Choose preventive maintenance operations and set a defensible frequency for each one
- Build a maintenance schedule as an actions × frequency table, readable at the workstation without verbal explanation
- Get the system up and running: display, weekly records, scheduling of level 2 tasks, handling of reported anomalies
- Spot the two classic drifts, over-maintenance and the box ticked without checking, and correct them
The path
- Getting out of the firefighter role: what a breakdown really costs 4 min
- Deciding who maintains what: levels 1 and 2, criticality analysis 5 min
- Choosing the operations and setting their frequencies 5 min
- Building the maintenance routine to be displayed at the workstation 4 min
- Keeping the system alive: collection, reporting, adjusting frequencies 4 min
Prerequisites
No methodological prerequisites. Knowing a machine in your workshop and knowing where its technical documentation is kept is enough. Having followed the topic on OEE helps to quantify the gains, without being essential.
The closing quiz
The topic ends with a 7-question quiz, and a certificate is issued on success.