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Approaches to Maintenance 120

Quality Training

Class Information

Tooling U classes are offered at the beginner, intermediate, and advanced levels. The typical class consists of 12 to 25 lessons and typically requires at least two hours of instruction time.

Class Name:	Approaches to Maintenance 120
Description:	This class provides an introduction to the maintenance profession and describes various approaches to the practice of maintenance.
Prerequisites:	none
Difficulty:	Beginner
Number of Lessons:	15

Class Outline

Objectives
The Importance of Maintenance
Evolution of Maintenance
Reactive Maintenance (RM)
Preventive Maintenance (PM)
Limitations of Preventive Maintenance
Predictive Maintenance (PdM)
Predictive Maintenance Techniques
Reliability-Centered Maintenance (RCM)
Elements of RCM
Total Productive Maintenance (TPM)
Selecting a Maintenance Approach
Scheduling Maintenance Work
Effective Maintenance Communication
Summary

Class Objectives

Explain the importance of maintenance work.
Describe the evolution of the maintenance profession.
Describe reactive maintenance.
Describe preventive maintenance.
Explain the limitations of a preventive maintenance approach.
Describe predictive maintenance.
Identify techniques used in predictive maintenance.
Define reliability-centered maintenance.
Describe the reliability-centered maintenance approach.
Define total productive maintenance.
Explain the factors involved in selecting a maintenance approach.
Describe methods for scheduling maintenance work.
Explain challenges of changing a maintenance program.

Class Vocabulary
autonomous maintenance		Maintenance performed by the machine operator rather than the maintenance staff. Autonomous maintenance includes tasks such as lubricating and tightening machine parts.
baseline readings		Measurements such as machine temperature or vibration taken while a machine is in working order. One of the first tasks when beginning a PdM program.
computerized maintenance management system		CMMS. Computer software used to plan and schedule maintenance activities.
condition-based maintenance		CBM. A maintenance technique closely related to PdM that involves monitoring machine condition and predicting machine failure. Many CBM systems are controlled by computers.
consultant		An expert hired by a company to provide advice and recommendations. A company may hire a maintenance consultant to help select a maintenance approach.
downtime		Unproductive blocks of time during which machine operations cease, often due to mechanical problems.
lean manufacturing		An approach to manufacturing that seeks to improve product quality and productivity, reduce costs, and eliminate waste. TPM is used in lean manufacturing.
lubricant		A substance used to reduce friction between two surfaces in relative motion. Oil and grease are common industrial lubricants.
lubrication		The act of applying lubricant to machines. Lubrication is a common task in preventive maintenance.
maintenance		The necessary and basic support and repair of machines. Maintenance includes tasks such as lubricating, adjusting, and replacing parts.
maintenance planner		A person who schedules and coordinates maintenance activities. Companies with large maintenance departments often hire maintenance planners.
planned downtime		A period of scheduled downtime for machine maintenance. Planned downtime is preferable to unplanned downtime caused by machine failure.
predictive maintenance		PdM. A maintenance approach that involves testing and monitoring machines in order to predict machine failures.
preventive maintenance		PM. Maintenance performed while a machine is in working order to keep it from breaking down.
reactive maintenance		RM. Maintenance performed only after a machine fails or experiences problems.
reliability-centered maintenance		RCM. A maintenance approach that prioritizes some machines over others to increase reliability and optimize financial resources.
run-to-failure		A maintenance policy that allows a machine to run until it breaks down, at which point reactive maintenance may be performed.
total productive maintenance		TPM. A manufacturing improvement method that increases production and reduces waste through continuous attention to the condition of machines and processes.
unplanned downtime		A period of unscheduled downtime, often due to machine failure.
vibration analysis		A PdM technique that uses instruments to monitor and analyze machine vibration to determine if the machine is working properly. Vibration analysis is of the most common techniques used in PdM.
waste		Any thing or process that does not add value to a product. The goal of lean manufacturing is to eliminate waste.