Preventive Maintenance

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A Health and Safety Guideline for Your Workplace

Preventive Maintenance
Why Preventive Maintenance?
Preventive maintenance is predetermined work

 Maintaining equipment service records  Scheduling replacement of components at the end of their useful service life  Acquiring and maintaining inventories of: – – – least reliable components critical components components scheduled for replacements

performed to a schedule with the aim of preventing the wear and tear or sudden failure of equipment components. Preventive maintenance helps to:  Protect assets and prolong the useful life of production equipment  Improve system reliability  Decrease cost of replacement  Decreases system downtime  Reduce injury Mechanical, process or control equipment failure can have adverse results in both human and economic terms. In addition to down time and the costs involved to repair and/or replace equipment parts or components, there is the risk of injury to operators, and of acute exposures to chemical and/ or physical agents. Preventive maintenance, therefore, is a very important ongoing accident prevention activity, which you should integrate into your operations/ product manufacturing process.

 Replacing service-prone equipment with more reliable performers By introducing the element of planning into your maintenance function, you are likely to reduce your repair and manpower requirements. Exploratory maintenance to anticipate and prevent breakdowns. Diagnostic measures to analyze your plant requirements include:  Operating and performing specifications of equipment  Past experience with components: – – – – – – – inspection records servicing records replacement frequency inspected component failures identify lubrication points on equipment colour code in order to identify lubrication frequency consult manufacturer and accepted industry best practices to establish schedule

What is Involved?
To be effective, your preventive maintenance function should incorporate the following elements: Planned replacements of components designed around the following:  Reliability of components (equipment failure is usually caused by its least reliable component) – – check manufacturer’s information check accepted industry best practices

 Regularly scheduled lubrication program:

Preventive Maintenance © Industrial Accident Prevention Association, 2007. All rights reserved.



Identifying Maintenance Hazards
The hazards associated with maintenance activities can be classified as follows: Safety Hazards  Mechanical – –       equipment tools



Work/process design – – – – poorly designed tools hard to access work locations ill fitting personal protective equipment complex procedures

Electrical – live equipment Pneumatic Hydraulic Thermal Combustion Falls – – slippery floors working at heights

Many of these hazards are interrelated. Examine your process, the layout of your process area, and the process equipment used, to determine the exact nature of the hazards likely to be encountered during your maintenance activities. For example, maintenance work carried out in confined spaces carries a greater risk of critical injuries and acute exposures to chemical and physical agents. These risks are associated with equipment and materials in the space itself and from nearby operations. Fatalities are quite common.

Controlling Maintenance Hazards
Ideally, the hazards likely to occur during maintenance activities should be addressed in the planning stage. Process Selection Depending on the nature of the process, special precautions may be needed to protect workers when disassembling and cleaning equipment. Consider this factor when you make a decision to select one process over another. Also consider the following factors which contribute to the level of risk of your maintenance activities:   How easy temporary structures are to erect How easy they are to access

Health Hazards  Chemical Agents – – – –...
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