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The equipment maintenance plan

The equipment maintenance plan

The Equipment Maintenance Plan, or EMP, not only identifies the specific tasks necessary to minimize failure mode consequences, but it also contains information that guides work order scheduling and provides pertinent information for budgeting maintenance resources and communicating downtime requirements to operations.

Reliability Solutions All sectors 26 June 2018

The elements of the EMP can be broken down into three categories of information: asset, task, and support.

An EMP only includes interval-based inspections and inspection-based activities designed to identify a failure mode, prevent a failure mode, or address activity that is statutory or regulatory in nature. An EMP is a detailed maintenance plan for the lowest maintainable item and includes the following:

  1. The equipment hierarchy.
  2. It needs to be clear to the end user which piece of equipment is being discussed or Identified
  3. Whether the client’s Computerized Maintenance Management System (CMMS) or Enterprise Asset Management system (EAM) hierarchy supports it or not, the hierarchy in the EMP needs to go down to the component level. Component is defined as the “lowest maintainable item” (i.e. pump, fan, motor, gearbox). Reference ISO 14224, Section 8.2 Taxonomy.
  4. The failure mode(s) that has/have been identified.
  5. The definition of a failure mode is “the part” + “what is wrong with the part” + “the reason”.
  6. The list of failure modes covered in an EMP need not be an exhaustive list. It should only include the predominant failure modes that represent both the failures that have happened and the failures that are likely to happen.
  7. The task(s) employed against each failure mode, divided into one of four categories.
  8. Inspection – identify the presence of a failure mode
  9. Preventative – prevent the occurrence of a failure mode
  10. Adjustment
  11. Time-based replacement
  12. Lubrication
  13. Run-to-failure
  14. Statutory or regulatory tasks – for liability reasons, the responsibility of defining these tasks and adding them to the EMP is reserved specifically for the asset owner
  15. The frequency for each task.
  16. Frequency is defined as interval based.
  17. Intervals can be defined in terms of time (hours, days, weeks) or throughput (units, tons, pounds).
  18. The person who is going to perform each task (by title not by name).
  19. Task assignments should be made based on task complexity and required skill levels.
  20. Operators may be assigned equipment care tasks or inspection tasks depending on task qualification.
  21. The amount of manpower that will be required to complete each task, reported in total man-hours.
  22. The amount of equipment downtime required to complete each task.

Once the EMP is developed and some failure history is collected, it can then be optimized. The optimization is accomplished through the use of powerful statistical sofware that analyzes failure patterns and accounts for the cost of failures.