Page 391 - Intro Predictive Maintenance

382 An Introduction to Predictive Maintenance

checks; any actions that are preventive of incipient failures. All work and actions are
planned. Preventive maintenance tasks, such as inspections, lubrication, calibration,
and adjustments, will be allocated to this cost classification. The intent of the main-
tenance improvement program is to increase the efforts in this classification to between
25 and 35 percent of total maintenance costs. In the SAP system, these tasks and activ-
ities will be assigned a priority code 6.

Repair. Includes all activities performed to restore an item to a specified condition,
or any activities performed to improve equipment and its components so that pre-
ventive maintenance can be carried out reliably. All costs associated with repair, cor-
rective maintenance, noncapital improvements, and rebuilds will be allocated to this
classification. Examples of tasks include diagnostics, remediation of damage, and
follow-up work and documentation. SAP priority codes 2, 3, or 4 will be assigned to
these tasks.

Condition Monitoring and Inspections. The activities are defined as all activities
involved in the use of modern signal-processing techniques to accurately diagnose the
condition of equipment (level of deterioration) during operation. The periodic mea-
surement and trending of process or machine parameters with the aim of predicting
failures before they occur. Included in these activities are visual inspection, functional
testing, material testing (all NDE/NDT), inspection, and technical condition monitor-
ing. These tasks will be assigned SAP priority code 6.

Training. This cost center is defined as training provided to the maintenance
workforce to enhance effectiveness. Examples of costs that should be allocated to
this cost center include proactive maintenance, life-cycle cost, and total cost of
ownership.

Turnarounds/Shutdowns. All activities required during a planned and scheduled tem-
porary operating unit shutdown to maintain or restore operating efficiency, inspect
equipment for purposes of mechanical or instrument/electrical integrity, and perform
tests and inspections. Examples of activities that should be allocated to this cost center
include major shutdowns and modifications of industrial systems and upgrading of
buildings, steel structures, and pipeline systems. These tasks will be assigned an SAP
priority code 5.

Improvements, Modifications, and Technical Innovations. All activities and measures
taken to improve/optimize plant performance that are not carried out as a part of a
project. This would include improvements relative to efficiency, availability, or safety
improvements. Also included are improvement of plant technology, adaptation to
current engineering requirements and regulations, and optimization of spare and
replacement parts inventory.

Regulatory Compliance. Cost for the initial actions taken to achieve compliance with
regulatory, safety, environmental, or quality requirements. For example, OSHA
1910.119, ISO 9000, FDA, Kosher, and others.