Equipment Maintenance Plan

Definition

The Equipment Maintenance Plan (EMP) is a list of the Preventive Maintenance (PM) and Predictive Maintenance (PdM) tasks that are going to be performed on the asset base, the frequency at which they are going to be performed, who will perform them, and how long each task will take. It is an engineered maintenance strategy based on failure modes of the component parts that replaces traditional PM activities with PdM technologies to reduce intrusive maintenance actions while increasing equipment availability.

How does iReliability™ enable this?

Preventive Maintenance Evaluation

Automatically eliminate, replace, or reassign PMs
Before a comprehensive EMP is developed, the existing EMP should be cleaned up. This cleanup process provides the organization with several benefits and begins with a Preventive Maintenance Evaluation (PME). Utilizing the PME tool, all PMs associated with the asset types within a facility as compared to those recommended by the EMP are assessed and assigned to one of the four following characteristics:

After the PM program is cleaned and retooled, the development of a comprehensive EMP can be initiated. iReliability™ uses a unique three-tiered method to develop the EMP.

Tier #1 – Standardized EMP (Asset Health Matrix)

Develop a highly customized EMP based on engineered failure modes in your plant
The Asset Health Matrix (AHM) tool utilizes the most reasonable and likely failure modes in asset components to identify which PM and PdM technologies and inspections could apply to the asset. Using benchmark data, each technology is assigned percent coverage models to populate the Asset Versus Technology Matrix.

Tier #2 – Customized EMP (RCM Blitz®)

Perform RCM analyses faster while simultaneously generating, communicating, and tracking RCM work requests

Using the asset criticality ranking index , the top 5-20% of the equipment will receive a complete RCM analysis. RCM Blitz® is a fully SAE JA1011 compliant RCM analysis methodology that focuses the analysis team on small portions of the plant, accomplishing rapid results. The output of the RCM Blitz® process is a complete maintenance strategy, from Condition Monitoring tasks to plans surrounding the run-to-failure components.

Tier #3 – Optimized EMP

Combine FMECA with your data to produce an optimized EMP
EMP optimization is accomplished through the use of powerful statistical software that incorporates the Failure Mode, Effects, and Criticality Analysis (FMECA) library developed with RCM Blitz® together with the failure data from your plant’s assets to produce an optimized maintenance strategy. The software model uses Weibull statistics and Monte Carlo Simulation routines to calculate the optimum maintenance strategy, failure mode by failure mode, over the entire life cycle of the asset.

Implementation

All of the proper design and information in the world is useless if not implemented. The iReliability™ team can assist you in implementing all maintenance designs and activities by integrating with your CMMS or populating import templates. This assures you that your investment of time, money, and energy will be recognized through proper execution of your desired EMP.

Learn more about iReliability’s Services here

Benefits/Values