Original Date: 11/03/1996
Revision Date: 01/18/2007
Information : Preventive Optimization Program
Oak Ridge Centers for Manufacturing Technology (ORCMT) has developed a Preventive Optimization Program (POP) which maintains essential structures, systems, and components (ESSC) by using a Reliability Centered Maintenance (RCM) philosophy. As an effective equipment reliability program, POP analyzes failure modes, uses performance indicators, and identifies the primary characteristics of ESSC for the safe operation of a facility.
ORCMT built the concept of POP around the integration of three major computer systems (the facilities’ database; the condition assessment survey; and the maintenance scheduling and planning software) to create an easy-to-use, homepage-based system. Via a point-and-click method, POP allows the user to search throughout the layers of a facility including total plant layout, individual building layout, system distribution diagrams, and individual component information. POP implementation required identifying components by unique component numbers; determining essential and non-essential components and structures; identifying maintenance requirements and failure rates; developing standard operating procedures, predictive maintenance techniques, and a spare parts inventory; tracking the benefits of the program from reductions in maintenance costs to increases in unit availability; and developing a monitoring system that uses constant feedback for continuous improvement.
Since developing the prototype, ORCMT has begun implementing POP in its facilities maintenance systems. For two of the systems analyzed, POP implementation will provide a $262,000 per year savings in maintenance labor and material costs. In addition, POP will redirect the maintenance program for the utilities and steam plant systems from 80% corrective maintenance and 20% preventive maintenance (PM) at startup to 25% corrective maintenance and 75% PM at full implementation. Other benefits from POP include reduced labor hours; increased system reliability; optimized maintenance and operational work forces; specific vendor documentation for each system; and a consistent master equipment list.
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