Quality Progress - December 2017 - 56

F E AT U R E

MAINTENANCE MANAGEMENT

a specific organization. Operating conditions, environment,
operator proficiency, equipment handling and equipment maintenance, for example, vary from organization to organization.
In PM, maintenance intervals also may depend on the historical
failure data within or outside an organization, which makes PM
a time-based maintenance interval strategy. Conversely, PdM
considers the actual condition of the equipment for proactive
maintenance planning and failure impact mitigation. This makes
it a condition-based maintenance interval strategy.
One of the strongholds of the PdM approach is to relieve
the maintenance plan's heavy dependence on past data, OEM
reports and industry data. Depending on an organization's own
unique operating environments, these data can vary in accuracy
and relevancy.
Tables 1 and 2 show how maintenance aspects compare in PM
and PdM, respectively.

Implementing PdM
After an organization realizes the benefits of PdM, the question
often asked is: How do you implement a PdM program? Before
starting a PdM program, it's imperative to remember that PdM
involves more than just implementing a simple program and
moving to the next assignment. PdM is a strategic direction
leading the way to efficient and proactive management of all
maintenance activities.

TA B L E 1

Preventive maintenance
Maintenance
type

Preventive
maintenance

56 QP

Maintenance
activity

End result

Equipment
breakdown
tracking

Generate a dedicated work order
for each failure, record repairs
made and equipment details,
and save the information for
future decision making.

Work
scheduling and
management

Organize, schedule and allocate
resources, such as repair crew,
maintenance facility and
supporting equipment.

Parts and
inventory
management

Manage parts in-flow and
spares, and make them available
based on maintenance needs.

Labor allocation

Plan and assign required
maintenance workers, and
record headcount, work hours
and overtime by individual task.

Costing

Calculate overall cost effect for
individual or aggregate tasks as
a result of labor work hours and
cost of parts.

December 2017 ❘ qualityprogress.com

Keeping that in mind, there are six steps to successfully establishing and sustaining a PdM program (Figure
1, p. 58):
1. Establish maintenance objectives. Determine what
features and capabilities the PdM program must have
to support the organization's specific maintenance
objectives. This ensures that the PdM program will
deliver a cohesive system that is intelligent, resilient,
autonomous and expansive enough to cover a multitude of factors affecting the
equipment's health.
It is important not only
 At this stage, decide which
to collect the data
areas or systems of the PdM
successfully, but also to
program should be implehandle it effectively and
mented first. Or, identify
generate useful insights
and prioritize the maintefor continuous learning
nance systems for gradual
and improvement of
implementation.
maintenance processes.
2. Adopt a condition monitoring program. Select a
condition monitoring program that supports all monitoring and data processing requirements identified in
the initial planning stage. The success of the proposed
PdM program hinges on selecting a condition monitoring program capable of delivering the organization's
desired PdM objectives.
3. Install sensors and smart systems. Next, install sensors and remote monitors on the equipment based on
the desired level of surveillance. Conditions typically
monitored include ultrasound measurement, vibration,
thermal scanning, oil and lubrication analysis, and
impact detectors.
 Smart systems capable of collecting, handling and
processing the gathered data and turning them into
intelligence also must be implemented. Several programs can do this, including machine learning toolkits
by Amazon, Microsoft, Databricks, Google, HPE and
IBM.
 These programs make use of machine learning,
artificial learning and other intelligence methods to
learn equipment performance patterns, known as
the equipment's normal condition, and quickly detect
any changes in those patterns, which may indicate
a potential failure. Some of these systems quickly
generate alerts for any adverse performance patterns,
predict failures and even suggest possible fixes.
4. Select a computerized maintenance management
system (CMMS). The CMMS software is essential to
simplify, manage and optimize maintenance activities
at all levels. When selecting a CMMS, consider whether


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Table of Contents for the Digital Edition of Quality Progress - December 2017

Seen and Heard
Progress Report
Mr. Pareto Head
Expert Answers
Career Coach
The Next Rung
Titles and Take-Home
Certification Certainty
Six Sigma Satisfaction
Stay the Course
Maintenance Makeover
Confronting Confusion
Standard Issues
Statistics Spotlight
Marketplace
Footnotes
Try This Today
Quality Progress - December 2017 - intro
Quality Progress - December 2017 - cover1
Quality Progress - December 2017 - cover2
Quality Progress - December 2017 - 1
Quality Progress - December 2017 - 2
Quality Progress - December 2017 - 3
Quality Progress - December 2017 - 4
Quality Progress - December 2017 - 5
Quality Progress - December 2017 - Seen and Heard
Quality Progress - December 2017 - 7
Quality Progress - December 2017 - Progress Report
Quality Progress - December 2017 - 9
Quality Progress - December 2017 - 10
Quality Progress - December 2017 - 11
Quality Progress - December 2017 - 12
Quality Progress - December 2017 - Mr. Pareto Head
Quality Progress - December 2017 - Expert Answers
Quality Progress - December 2017 - 15
Quality Progress - December 2017 - Career Coach
Quality Progress - December 2017 - 17
Quality Progress - December 2017 - 18
Quality Progress - December 2017 - 19
Quality Progress - December 2017 - The Next Rung
Quality Progress - December 2017 - 21
Quality Progress - December 2017 - 22
Quality Progress - December 2017 - 23
Quality Progress - December 2017 - 24
Quality Progress - December 2017 - 25
Quality Progress - December 2017 - 26
Quality Progress - December 2017 - 27
Quality Progress - December 2017 - 28
Quality Progress - December 2017 - 29
Quality Progress - December 2017 - Titles and Take-Home
Quality Progress - December 2017 - 31
Quality Progress - December 2017 - 32
Quality Progress - December 2017 - 33
Quality Progress - December 2017 - 34
Quality Progress - December 2017 - 35
Quality Progress - December 2017 - Certification Certainty
Quality Progress - December 2017 - 37
Quality Progress - December 2017 - 38
Quality Progress - December 2017 - 39
Quality Progress - December 2017 - 40
Quality Progress - December 2017 - 41
Quality Progress - December 2017 - 42
Quality Progress - December 2017 - 43
Quality Progress - December 2017 - Six Sigma Satisfaction
Quality Progress - December 2017 - 45
Quality Progress - December 2017 - 46
Quality Progress - December 2017 - 47
Quality Progress - December 2017 - Stay the Course
Quality Progress - December 2017 - 49
Quality Progress - December 2017 - 50
Quality Progress - December 2017 - 51
Quality Progress - December 2017 - 52
Quality Progress - December 2017 - 53
Quality Progress - December 2017 - Maintenance Makeover
Quality Progress - December 2017 - 55
Quality Progress - December 2017 - 56
Quality Progress - December 2017 - 57
Quality Progress - December 2017 - 58
Quality Progress - December 2017 - 59
Quality Progress - December 2017 - Confronting Confusion
Quality Progress - December 2017 - 61
Quality Progress - December 2017 - 62
Quality Progress - December 2017 - 63
Quality Progress - December 2017 - 64
Quality Progress - December 2017 - 65
Quality Progress - December 2017 - Standard Issues
Quality Progress - December 2017 - 67
Quality Progress - December 2017 - 68
Quality Progress - December 2017 - 69
Quality Progress - December 2017 - Statistics Spotlight
Quality Progress - December 2017 - 71
Quality Progress - December 2017 - 72
Quality Progress - December 2017 - 73
Quality Progress - December 2017 - Marketplace
Quality Progress - December 2017 - 75
Quality Progress - December 2017 - Footnotes
Quality Progress - December 2017 - 77
Quality Progress - December 2017 - 78
Quality Progress - December 2017 - 79
Quality Progress - December 2017 - Try This Today
Quality Progress - December 2017 - cover3
Quality Progress - December 2017 - cover4
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