Example of maintenance plan

A scheduled maintenance plan is nothing more than the set of ranges of

maintenance developed to address an installation. This plan contains all
the necessary tasks to prevent the main failures that can occur
installation. It is important to understand those two concepts well: that the plan of
maintenance is a set of maintenance tasks grouped into ranges, and
the objective of this plan is to prevent certain breakdowns

The technicians who have to tackle the job of creating a plan

maintenance is sometimes found without a model or a basis of
reference. This article aims to provide the reader with a possible model that can be
modified and improved at the discretion of the person performing the work.

Information that a maintenance range must have

A maintenance range is a list of tasks to be performed on equipment, in a

installation, in a system or even in a complete plant. The basic information
What a maintenance range should have is the following:

Team in which the task must be carried out

Description of the task to be performed
Result of the realization
Reference value, in the case that the task consists of a reading of
parameters, a measurement or an observation.

Tasks are grouped into ranges based on a common characteristic.

those that make it up. Thus, there are ranges by frequency (daily ranges, ranges
monthly, annual ranges, etc.) or by specialty (operation ranges, ranges
mechanics, electric ranges, predictive ranges, etc.

Daily games

The ranges or daily routes contain tasks that are easily performed. The majority
some of them refer to visual controls (strange noises and vibrations,
leak visual control), measurements (data collection, control of certain
parameters) and small cleaning and/or greasing tasks. In general, all the
tasks can be done with the teams running. They are the basis of a good
preventive maintenance, and allow to 'keep up to date' the plant. It is also, the part
easily transferable maintenance work to production staff
(or operation), and therefore can be better integrated into a TPM.

Due to the large amount of paper they generate (90% of the total after a year), not
it is advisable that they are in the Maintenance Management information system
Computer-Assisted. It is more practical to generate the roadmaps manually.
If they were generated by the computer system, the entire cycle would need to be completed.
from an O.T. (opening, approval, data loading, closing, approval of the closing,
etc.); all this effort is not justified, as it generates too much work
bureaucratic that adds no value.

After completing all the daily routes, it is advisable to fill out a report.
Incidents, reflecting all the anomalies observed in the plant.
from that part, an authorized person (a middle manager of
maintenance) or the operator in charge of carrying out the routes must generate
as many Work Orders as there are anomalies found.

WORK ORDERS

We can account for corrective maintenance work by the required work order.
that is to say, generating a format for easy quantification.

The format of the work orders must include data such as:

Department requesting it
Order date
Name of the executing department (sometimes there are several sections of
maintenance
Job description
Applicant's signature
Receipt signature. This signature belongs to the person in charge of the executing department.
Authorization signature. Here the production manager signs
Delivery date
Compliance signature of the work. When the work is received by the requester, they sign.
compliance.
Leaf

For our study, we will take into account the existence of a subdivision in the department of
maintenance: Electrical maintenance, Mechanical workshop, General maintenance and will be the example
what we will cover in this manual.

For the organization of work orders, as an example, we will divide the plant into different
departments starting with production and ending with offices.

Shears
2.Automatic lines
3. Semi-automatic dies
4.Automatic dies
5.Auxiliary closers
6.Warehouses
7. Production Offices
8. Quality Department
9.Management
 10. Safety and Hygiene
11.Systems
12.Human Resources
13.Accounting
14.Purchases
15.Sales
16. Maintenance
17. Dining room
18. Surveillance

We do not count the maintenance department when there are no subdivisions since it
It would generate duplicate or phantom orders, even when there is a count, as is the case.
From our example, we will ensure that the number of orders is minimal.

The simplest way to manage a log of this type is to organize it by months, into pending and completed.
the same that will give us an overview of the percentage of completion.
Format:

WORK ORDER

FOLIO NUMBER

DE:
ORDER DATE

DELIVERY DATE

FOR:

WORK RECEIVED SIGNATURE

JOB DESCRIPTION

APPLICANT RECEIVED AUTHORIZED

 Work order

In this industrial environment, the Work Order is a planning element.

which indicates, according to the cases and variants of each place, for each batch to
produce, order to be completed, specific products to be manufactured or similar:

* Los materiales que han de utilizarse y / o los realmente empleados.

* Las máquinas que han de intervenir
The necessary labor
The necessary plans, sketches, or diagrams
The administrative or order processing circuit
The necessary authorizations
The signature of the employees or the middle management involved in
that production.
The planning, production, and completion dates of the products
manufactured.
The times used

Its design can be very varied, but all or most of that data tends to
to appear in a Work Order. In its most classic format, we would have:

The references and codes of the Order

An area of the Order for Materials.
An area of the Order for Labor
An area of the Order for Machines
An area of the Order for sketches or drawings or for reference of plans
An area of the Order for signatures and authorizations
Indication of the sections or departments through which it must pass.

1.TIPOS DE MANTENIMIENTO • Las estrategias que se prevén son: • > Predictivo • > Preventivo • > Detectiv
> Correctivo • > Mejorativo.
2. Predictive Maintenance • Based on Condition, it involves inspecting equipment at intervals
regularly and take action to prevent failures or avoid their consequences according to the condition.
It includes both objective inspections (with instruments) and subjective inspections (with the senses), as well as repairs.
of the defect (potential failure)
3. Preventive Maintenance • Time-Based, consists of refurbishing or replacing at regular intervals
a team or its components, regardless of their state at that moment.
4. Detective Maintenance • Failure Search, consists of inspecting hidden functions at intervals.
regulares, para ver si han fallado y reacondicionarlas en caso de falla (falla funcional).
5. Corrective Maintenance • To the Breakage, it consists of the reconditioning or replacement of parts in a
Once the equipment has failed, the repair of the failure (functional failure) occurs urgently or in emergencies.
6. Improvement Maintenance • Redesigns, involves the modification or change of the original conditions of
team or installation. • It is not a task of maintenance per se, although maintenance does it.
7. MAINTENANCE PROGRAM
8. Work Orders • Provides access to all the necessary information for planning and
detailed work schedule (operations, labor, materials, and tools)
including costs, equipment, and failure analysis. • Allows for the daily introduction of requisitions of
maintenance work. • It keeps separate charges for labor, materials, and tools
to track costs, operation by operation. • It allows for cost analysis and
 Estimated working hours versus actual. • Schedule work orders based on critical level. •
It maintains equipment downtime statistics.
9. Preventive Maintenance • Generates preventive maintenance work orders on the date that
must be executed according to a specific condition. • Groups orders of
Preventive Maintenance to take advantage of equipment availability or downtime.
It has multiple criteria to generate a Preventive Maintenance work order. If a
The Master Plan must be executed based on frequency or maximum utilization time will be adopted.
nearest execution date. • Allows for predictive maintenance through plans
masters linked to pre-established alarm conditions.
10. Inventory • Provides ABC analysis, which divides the inventory into groups (based on cost or rate)
of the rotation of the pieces), • The costs and balances are updated instantly by the
purchasing and work order modules, making it possible to obtain figures at all times
real. • Shows all the elements of equipment in which a part is used. • Allows visualization
The work orders are related to each piece of inventory and include them to determine when
and how much should be reordered.
11. Activity Programmer • Generates work order programs using techniques of
resource leveling, by comparing needs against availability. • Optimizes scheduling
executing possibility analysis. • Analyzes and manipulates the scheduling of orders through
an interactive bar chart and a histogram. • Save the new scheduling dates for
then be compared with original dates.
12. Work Plan: Allows dividing the work plan into a sequence of operations with their
own spare parts, estimated labor and tools. • Extract information about
prices and costs, to make estimates on materials, labor, and tools.
Easily duplicable and modifiable.
13. Equipment • Record the maintenance cost of each equipment item over time.
Allows you to input and view detailed information about a specific type of equipment. • Performs
hierarchical list of equipment maintenance costs. • Build scales
hierarchical codes for recording equipment problems and analyzing them in the future.
Document Control function establishes and manages the relationship between the team and its
drawings/plans.
14. Purchases • Allows creating purchase requisitions directly, or from the inventory modules or
work orders. • It allows creating change orders to make modifications to orders of
approved or printed purchases. • Allows the creation of Global Purchase Orders to acquire parts.
in large quantities, over a specified period. • The Direct Purchase function allows
to order parts or services, and issue them to work orders or cost centers. • Allows
analyze the performance of suppliers when ordering parts.
15.Resources • Maintains records of companies, tools, and service contracts. • Groups together the
companies by type for report preparation. • Links a service contract to an order.
work. • Links multiple service contracts to a piece or equipment.
16. Labor • Use calendars to calculate labor availability and schedule the
work. • Controls vacation time, illness, unproductive work, attendance, absence and
the accumulated work of each employee. • Prepares reports on labor consumption
current in the work orders. • Keeps records of overtime by each specialty in the
organization.
17.Calendar • Allows entering multiple work shifts per day. • Allows scheduling work in
based on the availability of equipment and labor modules. • Allows viewing a calendar
monthly for each month and year, indicating the total hours available that day