The API Spec Q1 standard requires that organizations “maintain a documented procedure for the establishment of preventive maintenance for equipment used in product realization."  An effective PM program will reduce operating costs, improve product quality, and increase productivity for the company. Our goal is to minimize interruptions that  adversely impact productivity. With that in mind, we thought we would take this opportunity to discuss a number of best practices around the preventive maintenance process.
 
1. Preventive Maintenance factors:

Understand that preventive maintenance schedules are based on a variety of inputs, including:

• Usage history
  
• Risk analysis
  
• Manufacturer’s recommendations
• Industry recommended practices
• Regulatory requirements
• Internal experience
• Notable changes in system performance

2. Develop an actual plan

Most plans can be formed with a triggering mechanism. This means that certain events are slated to occur at a specific interval. The schedule may be developed with a condition-based or company-based protocol. The preventive maintenance schedule should always be assigned to a particular trigger.

3. Form the plan with savings in mind.
 
The plan should be developed with a specific set of savings objectives. Metrics like the maximum manufacturing time available for each machine may be used to create the schedule. There may be some downtime required where minimal lost production opportunity time may be factored into the planning process. There may even be a schedule developed around the concept affecting the quality of products manufactured.

4. Make the system available to others.
 
Once the framework has been constructed, the information should be created in some sort of a computerized maintenance system. The system will be formalized and assigned to key personnel responsible for monitoring the maintenance to be performed. The Accupoint system allows tasks to be automated and scheduled in a manner where work orders are generated on a timetable.

5. Set routine maintenance.
 
Once routine maintenance schedules are established for one system, move on to another critical system.  Again, set up maintenance schedules, documenting current conditions for future reference. An effective PM program can extend the asset life and ensures that it can be replaced as a scheduled event, rather than in an emergency situation.

6. Match the cost to the PM protocol developed.
 
It may be more cost-effective to perform a set of repairs simultaneously to a machine. It may also be much more cost-effective to take a reactive approach to maintenance. This approach may be better if this type of repair or maintenance duty doesn’t occur nearly as often.

In summary, a combination of inspections, repairs, and testing should be a part of any comprehensive preventive maintenance process. In addition,  any credible program should be long-term in nature.
 
To find out how Accupoint can help manage your preventive maintenance management program, call us toll free at 800-563-6250 or visit us at www.accupointsoftware.com.

Maintaining a management system that is effective, satisfactory and suitable is a requirement of the API Spec Q2 standard. In fact, section 6.5 states:

“The organization’s quality management system shall be reviewed at least annually by the organization’s management to evaluate the quality management system’s continuing suitability, adequacy and effectiveness.”

To that end, we thought we would discuss a couple of items to help streamline your Management Review planning.

When to Have a Review
The standard requires that you review your system annually, at a minimum. However, best practice dictates that you schedule your reviews more often, say quarterly and focus on specific aspects during each session. Ultimately,   this makes the process easier to manage and avoids duplication of efforts.

What to Include
When you are setting up your Management Review agenda, make sure to compile data for use in the discussion.  Include internal and third party audit results, customer complaints, non-conformities and corrective action requests.  Develop a schedule that allows you to review each aspect of the management system by the anniversary date.  Be sure to allow for a discussion period, to address areas for improvement as well as ways that the system should be monitored.

Upon completion, prepare action plans to address required changes to processes, resources, and other items identified in the review.

Documentation
Per the standard, the results of the Management Review must be documented and maintained.  In addition, top management must review and approve the summary assessment.  Results should be communicated with appropriate individuals throughout the organization.  Finally, the results should be used to drive continual improvement efforts within the organization.

To find out how Accupoint can help streamline your Management Review and related processes, please call toll free 800.563.6250 or visit us on the web at www.accupointsoftware.com.