Cover image for Fundamentals of preventive maintenance
Fundamentals of preventive maintenance
Gross, John M.
Personal Author:
Publication Information:
New York : AMACOM, [2002]

Physical Description:
xiii, 223 pages : illustrations ; 24 cm + 1 CD-ROM (4 3/4 in.)
General Note:
Includes index.
Subject Term:
Format :


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TS192 .G76 2002 Book and Software Set Non-Fiction Area

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Since the machines people depend on will always break down, companies need to institute preventive-maintenance management programmes in order to maximize equipment life and minimize downtime. This text outlines a systematic programme describing what needs to be done and why.

Author Notes

John M. Gross is a licensed professional engineer, a Six Sigma Black Belt, an ASQ Certified Quality Engineer, and an AFE Certified Plant Engineer. After seven years with the U.S. Air Force, he joined private industry. He has held several engineering and business positions in the food and automotive industries. His articles on the subject of productivity have been published in trade magazines around the world. Mr. Gross lives in Washington, Missouri

Table of Contents

Foreword and Acknowledgmentp. xi
The Best Way to Read This Bookp. xii
Chapter 1 Getting Startedp. 1
Taking Stock of Your Situationp. 1
Do You Need a Computer to Effectively Conduct Daily Maintenance and PM Activities?p. 2
Changing Your Plant's Concept of Maintenance and Employing Total Productive Workp. 5
What Are the Magic Steps to Implementing the Program?p. 7
Planning for Successp. 12
Summaryp. 14
Chapter 2 Establishing Schedulingp. 15
Why Do I Need to Schedule?p. 15
Establishing the Concept of Productive Workp. 16
How Do I Get Started?p. 16
What Do I Do with Workorders Once They're Completed?p. 30
Do Not Let the Workorder Scheduling System Crash and Burnp. 31
Summaryp. 35
Notep. 36
Chapter 3 Breaking Your Facility into Logical Partsp. 37
Define "Logical Parts"p. 38
How Do I Start the Process?p. 41
What Do I Do if I Maintain Buildings Instead of Plants?p. 45
Summaryp. 46
Test Timep. 48
Chapter 4 Developing an Equipment Listp. 51
Creating the Master Equipment List's Structurep. 53
Using Equipment Typep. 56
Let's Name Everything!p. 62
Creating the Master Listp. 63
Putting Equipment Numbers on Equipmentp. 65
Summaryp. 68
Test Timep. 69
Chapter 5 Writing PMsp. 73
Eat the Elephant One Bite at a Timep. 73
Elements of a PM Procedurep. 76
Writing Good Instructionsp. 76
Turning the Draft into Final PM Workordersp. 78
Scheduling PMsp. 80
Quality Assurance of PM Write-Upsp. 81
Summaryp. 83
Test Timep. 84
Chapter 6 Developing Equipment Manualsp. 85
Why Do We Need Manuals?p. 86
How Do We Create These Manuals?p. 87
Where Do We Get the Material for These Manuals?p. 89
What Goes in the Manual Under the "Other Significant Items" Heading?p. 90
What Are Troubleshooting Guides?p. 91
Reviewing, Editing, and Maintaining the Manualsp. 94
Summaryp. 95
Chapter 7 Setting Up Inventoryp. 97
A Quick Review of Inventory Managementp. 98
Inventory Management Stepsp. 99
How Do I Add New Parts?p. 114
What About Items That Never Get Used?p. 114
How Will Inventory Management Improve Uptime?p. 116
Summaryp. 117
Chapter 8 Maintaining the Systemp. 119
Why Does the World's Greatest Maintenance Management System Fail?p. 120
Maintaining Your Quality Levelp. 122
Keeping the PM Workorders Currentp. 124
What About Parts?p. 124
Making continuous Improvements (or Like a Shark, Move Forward or Die)p. 125
Learning from Your Failuresp. 132
More About CMMS Programsp. 134
Summaryp. 135
Test Timep. 136
Chapter 9 Planning for Successp. 139
Who Will Build the PMs and the Inventory?p. 140
What About the Long-Term Resources?p. 142
How Long Will This Take? I'm in a Hurry!p. 143
Summaryp. 148
Chapter 10 Conclusionp. 151
Appendix 1 Abbreviations Listp. 153
Appendix 2 Generic Equipment Listp. 155
Appendix 3 PM Procedure Worksheetp. 161
Appendix 4 Blank Formsp. 171
Work Performed Without a Workorderp. 172
Workorder, 8 1/2 x 11 Basicp. 173
Workorder, 8 1/2 x 11 Coordinationp. 174
Workorder, 8 1/2 x 11 Drawingp. 175
Workorder, 4 x 8 Size (Short Form)p. 176
Troubleshooting Guide Formp. 177
PM Quality Assurance Formp. 178
Parts Requisition Form, 8 1/2 x 11 Sizep. 179
Parts Requisition Form, 4 x 8 Size (Short Form)p. 180
Daily Shift Logp. 181
Action Planp. 182
Appendix 5 Test Time Answersp. 183
Appendix 6 Managing the System Without a Computerized PM Programp. 193
Appendix 7 Summary of Helpful Tipsp. 197
Indexp. 219
About the Authorp. 223