Page 393 - Intro Predictive Maintenance

384 An Introduction to Predictive Maintenance

It can be helpful, when specific parts are often needed for preventive maintenance, to
package them together in a kit. This standard selection of parts is much easier to pick,
ship, and use, compared to gathering the individual items. Plugs, points, and a con-
denser are an example of an automobile tune-up kit, while air filters, drive belts, and
disposable oilers are common with computer service representatives. Kits also make
it easier to record the parts used for maintenance with less effort than the individual
recording of piece parts. Any parts that are not used, either from kits or from
individual draws, should be returned to the stockroom.

With a computer support system, parts availability can be automatically checked when
the work order is dispatched. If the parts are not in the stockroom, the computer will
indicate in a few seconds by a message on the screen that “All parts are not available;
check the pick list.” The pick list will show what parts are not on hand and what their
status is, including availability with other personnel and quantities on order, at the
receiving dock, or at the quality-control receiving inspection. The scheduler can then
decide whether the parts could be obtained quickly from another source to schedule
the job now, or perhaps to place the parts on order and hold the work request until the
parts arrive. The parts should be identified with a work order so that receiving per-
sonnel know to expedite their inspection and shipment to the stockroom, or perhaps
can be shipped directly to the requiring location.

A similar capability should be established for parts that are required to do major over-
hauls and unique planned jobs. Working with the equipment drawing and replaceable
parts catalog, one should prepare a list of all parts that may possibly be required.
Failure-rate data and predictive information from condition monitoring should be
reviewed to indicate any parts with a high probability of need. Parts replaced on pre-
vious, similar work should also be reviewed—both for those that obviously must be
replaced at every teardown and for those that will definitely not be replaced because
they were installed the last time.

Once the list of parts needs is established, internal inventory should be checked and
available parts should be staged to an area in preparation for the planned work. Special
orders should be placed for the additional required parts, just as they are placed to fill
any other need.

Repairable Parts
Repairable parts should receive the same kind of advance planning. If it can be
afforded as a trade-off against reduced downtime, a good part should be available to
install and the removed repairable parts should be rebuilt later and then restocked
to inventory. If a replacement part cannot be made available, then at least all tools,
fixtures, materials, and skilled personnel should be standing by when the repairable
part is removed.

The condition of repairable parts, as well as those that are throwaways, should be eval-
uated as soon as convenient. The purpose is to measure the parameters that could lead