Preventive Maintenance Basics + AI Integration

Prioritize safety by conducting risk assessments and applying required precautions, implement lockout-tagout, inspect scaffolds, and prepare permits to prevent incidents and support near-miss reporting and root-cause investigations.

Compare preventive maintenance with corrective, predictive, and proactive strategies, and learn from the car example how inspections and replacements extend life, while noting preventive maintenance is not cost effective.

Explore preventive maintenance basics through a car example, guiding pre-trip inspections, leakage checks, oil and radiator levels, alarm assessment, and repair planning with a mechanic.

Analyze the car example to connect a global objective with preventive maintenance actions, using inspections, checks, and skilled labor to prevent breakdowns and ensure the equipment reaches its destination.

Plan and schedule preventive maintenance by ensuring spares, labor, and tools are available, and budget for parts, labor, and testing. Evaluate job quality through checks, commissioning, and reliability KPIs.

Define preventive maintenance strategy and identify the basic requirements to build and implement a successful program within maintenance management and planning basics.

Define preventive maintenance as regular, routine upkeep that keeps equipment running and reduces unplanned downtime. Plan and schedule maintenance before problems arise, and maintain accurate inspection records.

Remember the fundamentals of preventive maintenance basics to support reliable operation and proactive maintenance planning.

Explore the generic classifications of preventive maintenance, including time-based and frequency-based approaches, and how predictive or condition-based maintenance fits within the umbrella. Review PM activities like cleaning, lubrication, and inspections.

Explore the basics of preventive maintenance and its three components, and learn how planning and scheduling extend asset lifetime and boost performance toward production targets.

Explore the pros and cons of preventive maintenance strategy and recognize the advantages and disadvantages discussed in this chapter. Understand how preventive maintenance practices shape outcomes.

Explore the pros and cons of preventive maintenance and learn how proactive checks extend equipment life, reduce downtime, and improve reliability through planning and timely spare parts.

Remember the preventive maintenance basics and apply them to keep equipment functioning, minimize disruptions, and reinforce reliable maintenance practices across operations.

Explore the disadvantages of applying a preventive maintenance program, including budget pressures from time-based replacements and the benefit of condition-based checks like oil analysis to save costs.

Remember the preventive maintenance basics to keep equipment reliable and performance steady throughout your operations.

Review the advantages and disadvantages of preventive maintenance and show how staying ahead of failure through frequent overhauls, replacements, and equipment inspections helps plan replacement when a breakdown occurs.

Explore the main classifications of preventive maintenance, its types and examples, and note how classifications and responsibilities vary across industries and organizational structures.

Time-based maintenance schedules tasks at calendar intervals using OEM operating and maintenance manuals, grouping similar equipment; this approach can be costly and less efficient for rarely used or non-critical machines.

Identify time-based maintenance practices by examining examples like cleaning corrosion, checking bearing grease, changing lubrication oils, replacing filter components, and inspecting pressure and temperature gauges.

Explore meter-based preventive maintenance, where readings like running hours, miles, and pressure trigger timely service and scheduling of maintenance tasks.

Practice frequency-based preventive maintenance by replacing belts and motors at set intervals, changing oil at 10,000 miles, and checking gauges to ensure safe operation.

Explore predictive maintenance, a sensor-based method that monitors asset conditions, detects abnormalities, and triggers alarms or trips to save time, money, and effort, while noting upfront costs and training needs.

Explore predictive maintenance examples using thermal sensors to prevent overheating and vibration sensors on motors, pumps, and fans to detect abnormal spikes.

Explore prescriptive maintenance, an advanced asset maintenance strategy that uses machine learning, AI, and IoT with condition monitoring to predict failures and yield specific maintenance recommendations in real time.

Explore prescriptive maintenance and its advantages over predictive maintenance, using AI to adjust operating conditions such as pressure and speed to extend time to failure and meet demand.

Review the different types and examples of preventive maintenance, and emphasize that a combination of strategies, tools, and technology keeps plants running smoothly, healthy, and with fewer interruptions.

Identify catalysts and a supportive environment to create and stabilize a preventive maintenance culture, and explore the key factors essential for achieving a robust PM program.

Explore the critical pillars of preventive maintenance, including management, engineering, economic factors, and people psychology, and learn how these influence program success.

Top management sponsorship drives the PPM culture and ensures other management levels respect and rely on PPM results, with OpEx and sometimes CapEx budgets tied to preventive maintenance findings.

Cultivate a dynamic preventive maintenance program integrated into core business systems, with data reporting to leadership to foster accountability, drive PM culture, and secure organizational awareness of PM strategy.

Remember core preventive maintenance principles and routines to extend equipment life and reduce downtime through consistent application.

Design and implement preventive maintenance tasks with the right techniques and frequency, focusing on detecting or correcting critical wear through failure, uptime, and repair statistics within the engineering pillar.

Remember preventive maintenance basics to reinforce foundational understanding and prepare learners to apply preventive maintenance basics in real-world maintenance contexts.

Track maintenance cost as a key performance indicator to optimize spendings, compare PM costs to equipment cost, and assess equipment criticality to decide if PM is worthwhile, considering safety risks.

Balance the worth of preventive maintenance tasks by comparing failure costs to task costs, prioritizing actions that prevent downtime, environmental catastrophe, or loss of life.

Invest in people as your most important asset to build competitive advantage. Motivate the team and ensure they are technically capable to perform PM tasks through hands-on training.

Motivate the PM team to perform designated tasks consistently and accurately, ensure training and detail-oriented understanding, and recognize PM as a routine with room for creativity through technology and methodologies.

Remember the preventive maintenance basics, as introduced in this course, to establish a foundation for understanding maintenance practices.

Align the critical success factors across human, financial, engineering, and management pillars to guide the success journey of the preventive maintenance program.

Develop a preventive maintenance program by outlining basic steps and identifying information and data sources. Apply these basic steps across any industry to establish an effective maintenance strategy.

Break down facilities into a flow diagram, build a parent-child equipment list with tagging, standardize naming, issue maintenance instructions, locate manuals, establish inventory and scheduling, and monitor effectiveness for improvement.

Develop a codified assets list for your plant or facility, group similar equipment, and break each item into its main components to design preventive maintenance tasks.

In the design phase, start with equipment manuals, study them, break equipment into components; identify PM tasks, inspection checklists, and replacement frequencies, then consult OEM resources for the Femia Technique.

Develop a PM program from scratch with committed teammates, relying on O and M manuals and experiences. Continuously update tasks, frequencies, tools, and methodologies while ensuring safety and engagement.

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Identify the four major failure types—erosion, corrosion, fatigue, and overload—and show how corrosion stems from material loss while fatigue and overload arise from overloading components.

Understand erosion and wear from particles in a fluid or air medium contacting surfaces, causing abrasive or adhesive damage, and corrosion such as rusting of iron and steel.

Explore FMEA, a proactive engineering analysis that identifies potential failure modes and their effects in product design and manufacturing, to prevent or mitigate failures and assess impacts.

FMEA guides the preventive maintenance team to brainstorm failure modes and effects, break equipment into components, and design prevention, detection, or elimination strategies with maintenance schedules.

Apply the FMEA technique to predict bearing failure in a pump, and plan preventive maintenance with daily vibration checks, periodic vibration analysis, and six-month bearing replacement.