Preventive Maintenance (PM)

Preventive maintenance (PM) is defined at Michigan as a program in which wear, tear, and change are anticipated and continuous corrective actions are taken to ensure peak efficiency and minimize deterioration. PM involves a planned and controlled program of systematic inspection, adjustment, lubrication, and replacement of components, as well as performance testing and analysis. The result of a successful PM program extends the life of the facilities and equipment, and minimizes unscheduled downtime that causes major problems. It ensures that equipment is operating properly, and will improve the image of The University and Plant Operations, since unscheduled breakdowns are held to a minimum.

In 2000 we revamped our PM system to correct many shortcomings. The first step was the conversion of the existing NCR database into the new FM maintenance module. This FM scheduling tool is presently implemented. It allows us to keep a complete history of each piece of equipment on-line, and to easily sort equipment types by building or region.

Plant Engineering developed a three-year schedule to review all existing equipment in the database. The Work Management Group put together a team of equipment listers and data input personnel. The team reviewed building plans and then placed bar codes on all equipment in the buildings that were determined as requiring PM. The team entered all the information with equipment attributes into the AEC Maintenance PM Module. PM work orders are generated from the system at designated frequencies for each piece of equipment.

Plant Engineering immediately expanded and improved the PM program by taking a proactive role in the analysis of equipment, and identifying the most cost effective service tasks and time cycles. Vibration analysis of motors greater than 60 HP is one of the programs initiated by Plant Engineering.

Plant Engineering recommends service tasks and time intervals for all equipment in the PM system. As new equipment comes on line, a maintenance mechanic will gather nameplate data in the field. We will review the data, and assign initial service tasks and intervals before the data input personnel enters it to the PM system. As the PM system runs, a service/failure history will develop for each piece of equipment, and data can then be extracted by equipment type. Important elements within this operational phase that must be closely monitored include an assessment of appropriate PM tasks, as well as proper frequency. Equipment grows old, uses change, and techniques vary. An effective preventive maintenance program is not static, but needs regular review and updating in order to remain viable and effective. This will be Plant Engineering's key role in the program.

With several construction projects on campus, the PM system is used during the finishing stages of design to project annual maintenance costs for the new buildings. By using existing time data from pumps, fans, and other equipment, Plant Engineering can project annual cost to maintain our new buildings.