Efficient Plant June 2020 - 23

preventive maintenance

Cut Costs with PM
Optimization

Abel Galindo
Life Cycle Engineering

ONE ANSWER TO reducing maintenance costs is built into your existing
PM (preventive maintenance) program. Those "hidden" costs result from
performing unneeded/redundant maintenance and can be discovered by
implementing a PM-optimization program.

Implement a PM-optimization
program to ferret out hidden
waste in your maintenance
system.

+	

In some cases, PM programs include tasks for equipment
that no longer exists. When you consider maintenance
labor hours and parts, the cost of performing unneeded
work adds up very quickly. Another resource sponge is
equipment that has been changed and now requires different maintenance. There are also instances in which assets
have become obsolete and continue to be maintained.
Couple these factors with poor management-of-change
(MOC) practices that fail to register the changes and
assets get "lost" in the computerized maintenance
management system (CMMS).

+	

Performing unrequired maintenance should never happen.
A PM-optimization program can prevent this. Some
companies do a good job of bringing a new system
online, with the proper maintenance recommended by the
manufacturer. Problems occur when the system has been
in place for a couple of years and modifications are made.
A company that is on top of its MOC program will ensure
that adequate PMs are implemented, modified, or deleted.
	 This is not what usually happens, however. One
common example is something as simple as greasing AC
motors. Most companies are now realizing the benefits of
using sealed bearings. What typically happens is that a
motor is modified to use sealed bearings, but the information is never passed on or is not reflected in the CMMS
program. As a result, the existing AC motor greasing route
(PM) remains in the system, resulting in wasted time.

+	

Abel Galindo is a Reliability Technician with Life Cycle Engineering (LCE),
Charleston, SC (LCE.com). He has more than 25 years of experience in hands-on
engineering repair and supervision of engineering technicians. Preventive-maintenance
optimization is one of the asset-management strategies he develops for complex systems.
Abel can be reached at agalindo@LCE.com.

JUNE 2020	

EP2006rmclce.indd 23

PM optimization can also reveal redundancies. Again,
consider an AC motor that requires greasing every three
months with a certain amount of grease. It's not uncommon to have that same function entered in the CMMS as
an annual task and/or to not have the amount of grease
specified. Performing that annual task and/or adding too
much grease at any one time is a waste of labor hours and
materials. Even worse, adding excess grease could lead to
early motor failure.
PM optimization is a "living program" that never ends. It
should be part of every manufacturer's continuous-improvement journey. EP
EFFICIENTPLANTMAG.COM |

23

5/27/20 4:56 PM


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Efficient Plant June 2020

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