Preventive/Predictive Maintenance Optimization is a fundamental asset care process. PCA begins by analyzing core competencies as they relate to process and equipment functions. Operator, maintenance and engineering functions are addressed as they currently and potentially affect business reliability. This runs the gamut from housekeeping to vibration routes.

Our service provides the training and direction needed to asses, modify and optimize a plant’s repetitive, preventive and predictive maintenance activities. Intrusive maintenance inspections and services are minimized through reliability improvements. Studies have shown that over 30% of overhauled machines fail at start up, often causing collateral damage. In many cases, these machines were not in need of overhauling, or the need to overhaul could have been eliminated through more effective Preventive/Predictive Maintenance. Our focus is to provide the optimal level of asset care which typically includes the reduction of non-value added work and scheduled/unscheduled downtime.

This entire optimization process typically takes 40 days. The required time may be longer if there is no existing Preventive/Predictive program, and PCA’s assistance would be required in establishing one.

The optimization process requires three levels:

• Level 1. Activities include a “gap analysis”, a four-hour leadership workshop, and the preparation of a detailed plan and schedule for optimization of Preventive/Predictive Maintenance activities and correction of gaps. Programs such as Process Safety Management, MSHA, and ISO are included as required.
• Level 2. At this level, activities will involve the definition of the individuals who will be part of the Preventive/Predictive optimization process. Once this organization is established, detailed training is provided, current technology gaps are corrected, and the data and reporting network and procedures put in place.
• Level 3. Activities involve the hands-on application of the Preventive/Predictive optimization principles, tools and data collection to the actual plant equipment. During this step, the Master Maintenance Schedule of repetitive tasks is developed and actual Preventive/Predictive routes are established or modified. These are then integrated into routine work schedules for daily and repair-day (outage) work. The feedback loop is established and actual data is collected and analyzed for continuous optimization of Preventive/Predictive activities. PCA will assist in the assessment and application of Preventive/Predictive technologies to include lubrication, vibration monitoring, shock pulse, thermography, ultrasonic emission, etc. Basic PM Templates are provided to initiate or enhance a proactive asset care process. These templates are designed to be applied against generic families of equipment for industries such as manufacturing, mining, petrochemical and pulp and paper, or they can be adapted to be more specific if needed.

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