Introduction to Preventive Maintenance

IBM Maximo Preventive Maintenance helps you reduce Assets downtime and increase operational efficiency.

Let us assume we are looking at a big plant, with thousands of Assets and ample Equipment. Running such a plant without having a maintenance strategy in place is a plan to fail.  That’s why, most of the organizations choose a specific maintenance strategy to follow, whether it’s Preventive, Corrective, Risk-based or Condition monitoring. One can also choose different strategies based on criticality and sensitivity of Assets.

Preventive Maintenance (PM) is the planned maintenance work that should be regularly performed on a piece of equipment to mitigate the risk of unexpected failures. Required resources would also be planned to guarantee availability of Labour, Services and Goods when needed in a PM.

The simplest example that everyone can relate to is that of car maintenance. Cars factories set the PM plan for each car based on the engine specification and the technology used in the specific model. The recommendation of having the car serviced every 6 months or 8,000 km, whichever is reached first, is an example of a PM plan for a car. One can choose to apply the recommended plan so the car does not break down unexpectedly or apply another maintenance strategy, such as Corrective Maintenance Strategy, where by one chooses to wait until there is a failure and then identify the work that needs to be done to fix the car and set it back to normal operation. The same is applied for Assets in any machinery-based industry.

Even with a Preventive Maintenance Strategy, there will always be Preventive Maintenance Work overlapping with Predictive Work, in addition to Unexpected Failures. However, the percentage of unexpected failure work reflects the reliability of the maintenance strategy applied in the organization and the effectiveness of the Maintenance Plan in place.

Choosing a maintenance strategy is just the beginning; the following step is the most challenging; setting up a detailed preventive maintenance plan for each and every Location, Machine or Asset as required. Organizations can spend years building their PM Plan and they keep reviewing and improving it based on the Failure Analysis outcome. This is still rewarding because improving PM will decrease the percentage of unexpected failures which will, in turn, decrease the cost of operation and total cost of ownership. However, automation of PM program and ongoing improvement require intensive data capturing. Auditing, failure analysis and financial reporting of Operation and Maintenance Costs provide input for the process of monitoring & Controlling the PM Plan.

Maintenance Management Solutions

Enterprise Asset Management (EAM) software helps you optimize the maintenance process, minimize the costs and maximise the return on investment. With Asset tracking, Meters Reading, Preventive Maintenance, Condition Monitoring, Work Management, Inventory Management and a lot more, the IBM Maximo asset management solution helps you reduce assets downtime and increase operation efficiency. IBM Maximo design, add-ons and industry solutions meet the business needs of multiple industries including: Transportation, Nuclear, Life Sciences, Utilities and Oil& Gas.

Learn more about IBM Maximo Asset Management.

With respect to Preventive Maintenance, IBM Maximo provides a solid and complete solution to automate and manage the PM program. Without going into the detailed process, I’m listing herein some of the core functionalities covered by the Maximo PM Process:

  • Plan and Track your PM activities based on the Location and/or Asset: PM records in IBM Maximo can be set against Locations, Assets or a Route. A Route is a number of related Assets or Locations that require the same PM. One can always search and retrieve current or historic PM records against specific equipment(s).
  • Plan required resources, such as Material, Labour and Services: Each PM can have one or more Job Plan. A Job plans is a planned predictive group of tasks to be executed in a specific sequence to perform a specific work. Job Plans includes information of expected duration and required resources. When a Job Plan is linked to a PM, the WO generated from that specific PM will include the tasks and planned resources specified in the related Job Plan.
  • Set a Frequency of PM, be it time-based, meter-based or a combination of both: PM can be set to trigger Work Orders based on elapsed time from previous work (time-based), when a meter reading reaches a specific value (meter-based) or a combination of both. For example, you can schedule a PM that triggers work every six months or every 300 operating hours, whichever comes first.
  • Set the basic information of the Work Order to be triggered by the PM: Information associated with a PM becomes part of the work orders generated from the PM. For example, each Job Plan Task will become the task of the related work orders.
  • Set Seasonal PM plans where applicable: In each PM within IBM Maximo you can specify active hours, days, weeks or months. That would force Maximo to only generate work orders on those time periods. For instance, one can set the active working days as Monday to Friday and instruct the System to shift the schedule back for maintenance tasks falling in a weekend. The same logic can be applied on working hours/shifts. Furthermore, seasonal PM can be set in IBM Maximo, so a specific PM can be active during summer while another one can be active during winter.
  • Identify the correct sequence of Job Plans: in some cases, different maintenance work need to be done based on the time/meter reading. For example, an Asset can have a PM record with 2 Job Plans; Plan (A) that includes the quarterly maintenance tasks and Plan (B) that includes the annually maintenance tasks. The Job Plan sequence set within the PM record will identify the correct Job Plan for each generated Work Order.
  • Review the Forecast of the Predictable Work to be triggered by the PM: IBM Maximo has a PM Forecasting Functionality that generates forecasts for preventive maintenance records within a provided period of time. Forecasts are based on the frequency criteria and seasonal information specified in the PM record. One can review the PM forecast to confirm the PM has the correct setting and it will trigger work when expected.
  • Generate Work Orders: PM Work Orders Generation can be done manually or automatically. To automate the process, a CRON task can be set to generate the PM Work Orders based on the criteria that the business provides.

Read the IBM Maximo Asset Management product sheet.

Furthermore, IBM Maximo and a number of available add-ons provide additional functionality to manage, control and monitor the work across the organization. Processes of Work Management, HSE, Investigation, Risk Assessment and Failure Analysis are well catered for in Maximo and they can be effectively used to Audit and Improve the Maintenance strategy and the PM program whenever required.