Page 390 - Intro Predictive Maintenance

A Total-Plant Predictive Maintenance Program 381

classifications and how they will be used to support the maintenance improvement
process. Date collected in the eight “cost buckets” will be used to develop perfor-
mance indicators, maintenance strategy, realistic maintenance budgets, and benchmark
data.

Work Orders
All work done on equipment should be recorded on the equipment record or on related
work order records that can be searched by equipment. The equipment failure and
repair history provide vital information for analysis to determine if preventive main-
tenance is effective. How much detail should be retained on each record must be
individually determined for each situation. Certainly, replacement of main bearings,
crankshafts, rotors, and similar long-life items that are infrequently replaced should
be recorded. That knowledge is helpful for planning major overhauls both to deter-
mine what has recently been done, and therefore should not need to be done at this
event, and for obtaining parts that probably should be replaced. There is certainly no
need to itemize every nut, bolt, and lightbulb.

Cost Distribution
Maintenance improvement depends on the ability to accurately determine where costs
are expended. Therefore, the SAP R-3 CMMS must be configured to accurately
capture and compile maintenance cost by type, production area, process, and specific
equipment or machinery. This task is normally accomplished by establishing a work
breakdown structure that will provide a clear, concise means of reporting expendi-
tures of maintenance dollars. Within the SAP system, cost will be allocated into the
following eight classifications:

• Emergency
• Maintenance
• Repair
• Condition monitoring and inspections
• Training
• Turnarounds/shutdown
• Improvements, modifications, and technical innovations
• Regulatory compliance

Emergency. All work performed in response to actual or anticipated emergency break-
downs, OSHA-reportable incidents, and safety-related repairs will be charged to the
emergency classification. The intent of the maintenance improvement process is to
eliminate or drastically reduce the percentage of time and cost associated with this
type of work. In the SAP system, these tasks and activities will be assigned priority
code 1.

Maintenance. As defined as, all activities performed in an attempt to retain an item
in specified condition by providing systematic, time-based inspection and visual