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Preventive and Corrective Maintenance - Looking for a basic procedure


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preventive maintenance, procedures (general)
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  Post Number #1  
Old 16th June 2004, 12:49 PM
Randy's Avatar
Randy

 
 
Total Posts: 8,399
Please Help! Preventive and Corrective Maintenance - Looking for a basic procedure

I've bit off so much I am now starting to choke......

Does anyone have a generic (or one that can be changed) preventive maintenance procedure for production support equipment like banding machines, pallet jacks, material dollies, floor fans, and all that kind of stuff?

What I'm looking for is a basic procedure outlining how communication of maintenance needs can be handled, any supporting forms and so on, and the actual maintenance process itself.

I've stepped into a situation where there is no defined way to address how to tell the appropriate party that something is broke that has to be fixed.

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  Post Number #2  
Old 16th June 2004, 01:24 PM
ralphsulser's Avatar
ralphsulser

 
 
Total Posts: 1,573
Randy,
I'll attach some forms we use, may help
Attached Files: 1. Scan for viruses before using, 2. Please report any 'bad' files by Reporting this post, 3. Use at your Own Risk.
File Type: xls COOLING TOWER WATER PUMP PM-411.xls (21.0 KB, 565 views)
File Type: xls MT-SD-001 PM SCHEDULE 2004.xls (18.5 KB, 713 views)
File Type: xls HOIST PM-413.xls (26.0 KB, 493 views)
Thank You to ralphsulser for your informative Post and/or Attachment!
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  Post Number #3  
Old 16th June 2004, 01:56 PM
Douglas E. Purdy's Avatar
Douglas E. Purdy

 
 
Total Posts: 546
A General Flow

Quote:
In Reply to Parent Post by Randy

I've bit off so much I am now starting to choke......

Does anyone have a generic (or one that can be changed) preventive maintenance procedure for production support equipment like banding machines, pallet jacks, material dollies, floor fans, and all that kind of stuff?

What I'm looking for is a basic procedure outlining how communication of maintenance needs can be handled, any supporting forms and so on, and the actual maintenance process itself.

I've stepped into a situation where there is no defined way to address how to tell the appropriate party that something is broke that has to be fixed.
Randy,

Here are two general flows for a process that did not have a Computerized Work Order & Scheduling System. If you want examples of forms, let me know. Hope this helps.

Doug
Attached Files: 1. Scan for viruses before using, 2. Please report any 'bad' files by Reporting this post, 3. Use at your Own Risk.
File Type: vsd A Maintenance Flow pg1.vsd (113.5 KB, 1744 views)
File Type: vsd Infrastructure PM pg1.vsd (98.0 KB, 741 views)
Thank You to Douglas E. Purdy for your informative Post and/or Attachment!
  Post Number #4  
Old 16th June 2004, 03:03 PM
Wes Bucey's Avatar
Wes Bucey

 
 
Total Posts: 11,036
Quote:
In Reply to Parent Post by Randy

I've bit off so much I am now starting to choke......

Does anyone have a generic (or one that can be changed) preventive maintenance procedure for production support equipment like banding machines, pallet jacks, material dollies, floor fans, and all that kind of stuff?

What I'm looking for is a basic procedure outlining how communication of maintenance needs can be handled, any supporting forms and so on, and the actual maintenance process itself.

I've stepped into a situation where there is no defined way to address how to tell the appropriate party that something is broke that has to be fixed.
Take a look at the kinds of things that Google finds when you enter:
"pallet jack" +maintenance
"fork truck" +safety

Also look at manufacturer websites to see what they offer in the way of handouts, procedures, checklists, etc.

Once you have some of these in hand, you might consider a top level safety procedure which says (even in flow chart form):
We want our operators to be safe when they operate any of the equipment in our plant. The best way to insure your safety is to know
  1. how to operate your equipment,
  2. how to check to ensure it is in proper condition for operation, and
  3. how to perform simple preventive maintenance procedures to keep it in safe running condition.
  4. what to do when the equipment needs repair
Then issue a checklist (laminated cover?) specific to the equipment that stays with each piece of equipment, similar to what pilots do prior to takeoff.
  Post Number #5  
Old 16th June 2004, 03:41 PM
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Randy

 
 
Total Posts: 8,399
Thanks so much...

What I ran across was a small piece of equipment that is used on a continual basis to help band material for shipment. The bander looks like a material dolly (2 wheels, a handle and all that), and 1 of the wheels was missing causing the employees to drag it from place to place. When I asked a supervisor why this thing hadn't been fixed (3-4 month old problem) I got the old "I told everyone so it's not my problem/responsibility" routine. Apparently there is no organized (formalized) process for requesting basic and performing maintenance/repair on infrastructure and support equipment (catch as catch can maintenance). No documents, no procedures, no records, NADA!

How to fix an item isn't the issue....how to get it fixed and to prove that we did so is.
  Post Number #6  
Old 16th June 2004, 07:29 PM
Wes Bucey's Avatar
Wes Bucey

 
 
Total Posts: 11,036
Quote:
In Reply to Parent Post by Randy

Thanks so much...

What I ran across was a small piece of equipment that is used on a continual basis to help band material for shipment. The bander looks like a material dolly (2 wheels, a handle and all that), and 1 of the wheels was missing causing the employees to drag it from place to place. When I asked a supervisor why this thing hadn't been fixed (3-4 month old problem) I got the old "I told everyone so it's not my problem/responsibility" routine. Apparently there is no organized (formalized) process for requesting basic and performing maintenance/repair on infrastructure and support equipment (catch as catch can maintenance). No documents, no procedures, no records, NADA!

How to fix an item isn't the issue....how to get it fixed and to prove that we did so is.
If the strapping (the preferred term over "banding") is steel - odds are the machine came from Signode or Uline - both companies have excellent PR for stuff like you need.

Google search would probably be (strapping + steel) or (strapping +plastic) using "strapping" will eliminate the hits for those steel bands that play island music.
  Post Number #7  
Old 16th June 2004, 11:06 PM
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Randy

 
 
Total Posts: 8,399
The strapping isn't a problem and the equipment isn't a problem, getting the stupid thing on 2 wheels is the issue....I found a dozen replacement wheels in less than 15 minutes at a Home Depot and another 6 or so at a nearby Ace Hardware....the issue is a guidance document that says "when junk breaks, here's what you must do to get it fixed"...

I was hoping someone had a down and dirty, basic procedure.
  Post Number #8  
Old 17th June 2004, 09:46 AM
C Emmons

 
 
Total Posts: 307
Quote:
In Reply to Parent Post by Randy

The strapping isn't a problem and the equipment isn't a problem, getting the stupid thing on 2 wheels is the issue....I found a dozen replacement wheels in less than 15 minutes at a Home Depot and another 6 or so at a nearby Ace Hardware....the issue is a guidance document that says "when junk breaks, here's what you must do to get it fixed"...

I was hoping someone had a down and dirty, basic procedure.
I dont know if this is the type of information you are looking for, but. If we have equipment needing repair, anyone has the ability to place an out of service tag, write it up (usually we use a standard vehicle inspection report for tractors, trailers, forklifts etc. Once the equipment is tagged out of service it is placed in a designated area and the report sent to mainteance. If we consistently end up with lots of equipment needing repair and it is impacting peoples ability to do their jobs, a formal corrective action is issued to managment.
Thanks to C Emmons for your informative Post and/or Attachment!
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