Looking for Equipment Specific Preventive Maintenance templates/Procedures/forms

S

skiman

#1
I am looking for Equipment Specific Preventive Maintenance templates/Procedures/forms that I can modify for our equipment requirements.
For example: for a large industrial centrifugal fan, once we have listed the lockout/tagout requirements what tasks should we list for the technician to perform and what check list items should be included.
I am looking for templates we can modify for a general industrial manufacturing/processing plant, I do not expect a generic form/template to be adequate for our purposes without modification.

Thanks in advance!
 
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Randy

Super Moderator
#2
Here's a unique thought...Why not ask someone who is actually a maintenance expert to help? You know, someone who on a daily basis gets their hands dirty actually maintaining equipment. An expert, so to speak.

If I were needing information about cooking procedures I'd go to a professional cook instead of a car mechanic.
 

Marc

Hunkered Down for the Duration with a Mask on...
Staff member
Admin
#3
Don't let Randy get to you. There might be some experts here.

I will say this may be too specific as there are often differences in brands, etc. E.g. One motor may have sealed bearings whilest another may need to be oiled at a specific interval. When writing maintenance procedures it is usually best to look at the manufacturers manual that came with the equipment. Usually a manufacturer will at least give a 'minimum' maintenance schedule.

Does anyone here have anything as specific as the thread starter is looking for?
 

harry

Super Moderator
#5
Equipment specific maintenance? Procedures? Templates?.

I thought the best source is the machine manual. Who knows better than the designers and manufacturers? And who can say that you did not do a good job if you follow the manual?
 

Cari Spears

Super Moderator
Staff member
Super Moderator
#6
Hi skiman - welcome to the cove.:bigwave:

Here are the simple maintenance charts we use. These are the tasks that each machine's main operator is responsible for. Each machine has its own and the requirments come from (as already suggested) our machine maintenance expert and the manuals for the machines. You'll notice that the machine manuals are referenced in them here and there for more in-depth instruction if needed.
 

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S

skiman

#7
Thanks for these interesting comments.
I am sure that there are "experts" here, it is obvious from looking at the forums.
The facts are that most equipment mfg's simply do not provide much more than to say, "Perform appropriate maintenance tasks, check equipment condition including drivers, foundations, and controls".
I agree that the operators and mechanics should be the "In-house Experts". Unfortunately a discussion with them often goes like this, "What was the final installed belt tension?"
"I tightened them!"
"How tight, what spec's were used and the tension tester reading?"
"I know how tight they need to be, I know how to do my job!"
They often view procedures and checklists as a controls issue and a method to place blame and judge them; rather than guidelines to insure that an activity has been properly completed, an historical record, and a feedback loop to facilitate efficiency and effectiveness improvements.
I realize that correctives for this barrier will not be implemented through PM's but those actions are outside of my direct influence.
I can issue PM's that facilitate feedback, then the accountability defaults to those with influence responsibility.
Were I free to construct PM's as I prefer, I would use the Center for Chemical Process Safety (CCPS) guidelines, ISO or others. However that is not my mandate.
I am hoping that someone will already have developed templates with indicated tasks so I will not need to reinvent what has already exists. I do expect that I will have to change and customize them to include specifications and tolerances (Like belt tension and alignment), but I would prefer to start with a baseline.
The file I have attached is my start for a fan, but we have everything from kilns, dryers, conveyors, incinerators to pumps and everything in between!
Thanks in advance!
 

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Craig H.

#8
Skiman,
We have something VERY similar to what Cari has (its almost spooky how close). I suggect you use Excel, and turn on the gridlines in Page Setup so that the grids will print. And DO print them (even in our move towards less paper I will continue to demand this). There are some nice metal clipboards available that can hold the forms and also withstand being taken out into the plant. Encourage your folks to take the checklist out into the plant with them, and check off each item as it is done. Also, if more than one type of grease/oil is used, indicate what type to use for each bearing, and how much, right on the form. My goal, as these were developed years ago, was for these to serve as a reminder and a guide. The audit trail, if needed, is an added bonus.

As far as attitudes go, since we are 24/7, and there are 4 operators for each position, they do a pretty good job of policing themselves, and the checklists get looked over by me during audits. Rarely is there a problem.
 
J

jimmydqc

#9
Your forms are great...very detailed. Do the operators/machinists resist or put off filling them out at the scheduled intervals?
 
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