Preventative Maintenance and ISO 13849 Freelance Ready Assessment (Publication Date: 2024/03)


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Discover Insights, Make Informed Decisions, and Stay Ahead of the Curve:

  • Have preventative maintenance procedures been developed for all field instrumentation?
  • How does your organization spread the cost of a Preventative Maintenance contract over the entire year?
  • Does facility have a documented preventative maintenance program to minimize equipment downtime?
  • Key Features:

    • Comprehensive set of 1513 prioritized Preventative Maintenance requirements.
    • Extensive coverage of 115 Preventative Maintenance topic scopes.
    • In-depth analysis of 115 Preventative Maintenance step-by-step solutions, benefits, BHAGs.
    • Detailed examination of 115 Preventative Maintenance case studies and use cases.

    • Digital download upon purchase.
    • Enjoy lifetime document updates included with your purchase.
    • Benefit from a fully editable and customizable Excel format.
    • Trusted and utilized by over 10,000 organizations.

    • Covering: Health And Safety Regulations, Respiratory Protection, Systems Review, Corrective Actions, Total Productive Maintenance, Risk Reduction, Emergency Stop System, Safety Certification, Circuit Design, Machine Control Systems, System Architecture, Safety Requirements, Testing Procedures, Guard Design, Human Factors, Emergency Procedures, Regulatory Compliance, Root Cause Analysis, Safety Training, Software Design, Record Keeping, Safety Checks, Operating Procedures, Reference Documentation, Environmental Safety, Crane Safety, Hazard Analysis, Failure Analysis, Chemical Handling Procedures, Occupational Health, Control System Engineering, Diagnostic Testing, Personal Protective Clothing, Industrial Hygiene, Personal Protective Equipment, Hazardous Energy Control, Control System Safety, Failure Mode And Effects Analysis, Safety Policies, Safety Manuals, Equipment modification, Emergency Release, Communications Protocol, Employee Rights, Programmable Systems, Risk Mitigation, Inspection Checklist, ISO 13849, Hardware Design, Safety Ratings, Testing Frequency, Hazard Identification, Training Programs, Confined Space Entry, Fault Tolerance, Monitoring System, Machine Modifications, Safe Speed, Process Hazard Analysis, Performance Level, Electrical Equipment Safety, Protective Equipment, Injury Prevention, Workplace Safety, Emergency Response Plan, Emergency First Aid, Safety Standards, Failure Investigation, Machine Guarding, Lockout Tagout Procedures, Policies And Procedures, Documentation Requirements, Programming Standards, Incremental Improvements, Failure Modes, Machinery Installation, Output Devices, Safe Direction, Warning Signs, Safety Functions, Fire Prevention And Response, Safety Culture, Safety Labels, Emergency Evacuation Plans, Risk Assessment, Safety Distance, Reliability Calculations, Job Hazard Analysis, Maintenance Schedules, Preventative Maintenance, Material Handling Safety, Emergency Response, Accident Investigation, Communication Network, Product Labeling, Ergonomic Design, Hazard Communication, Lockout Tagout, Interface Design, Safety Interlock, Risk Control Measures, Validation Process, Stop Category, Input Devices, Risk Management, Forklift Safety, Occupational Hazards, Diagnostic Coverage, Fail Safe Design, Maintenance Procedures, Control System, Interlocking Devices, Auditing Procedures, Fall Protection, Protective Measures

    Preventative Maintenance Assessment Freelance Ready Assessment – Utilization, Solutions, Advantages, BHAG (Big Hairy Audacious Goal):

    Preventative Maintenance

    Yes, preventative maintenance procedures have been created for all field instrumentation to ensure their proper functioning and avoid potential issues.

    1) Yes, regular preventative maintenance reduces risk of failure.
    2) Benefits include longer lifespan and improved reliability.

    CONTROL QUESTION: Have preventative maintenance procedures been developed for all field instrumentation?

    Big Hairy Audacious Goal (BHAG) for 10 years from now:

    In 10 years, our company will have implemented an advanced system for preventative maintenance that covers all field instrumentation. This system will utilize cutting-edge technology and data analytics to identify potential issues and proactively address them before they result in costly breakdowns or downtime. Our procedures will be streamlined and highly efficient, using predictive maintenance methods to optimize the lifespan of our equipment and ensuring maximum productivity for our clients. Through continuous improvement and a commitment to innovation, our preventative maintenance program will set the industry standard and solidify our position as a leader in the field of instrumentation maintenance.

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    Preventative Maintenance Case Study/Use Case example – How to use:

    Client Situation:

    ABC Manufacturing is a leading player in the chemical industry, with multiple production facilities located globally. The company has a diverse product portfolio, and its operations involve the use of a broad range of field instrumentation, including sensors, transmitters, controllers, and valves. These instruments are crucial for monitoring and controlling critical process parameters and ensuring the safety and quality of the products. Any failure or malfunction of these instruments can have severe consequences, including production downtime, product quality issues, and safety hazards.

    The company has been facing frequent instances of instrument failures, leading to disruption of production, quality defects, and safety incidents. These failures have resulted in significant financial losses and damage to the company′s reputation. Moreover, the maintenance costs have been escalating, as the company has been following a reactive maintenance approach, i.e., fixing issues only after they arise.

    To address these challenges, ABC Manufacturing has engaged our consulting firm to develop preventative maintenance procedures for all field instrumentation. The primary objective is to ensure optimal performance, minimize failures, reduce maintenance costs, and improve overall operational efficiency.

    Consulting Methodology:

    Our consulting methodology involves a thorough analysis of the client′s current maintenance practices, identification of critical instruments, development of preventative maintenance procedures, and implementation support. The following steps were undertaken to achieve the project objectives:

    1. Current Maintenance Practice Analysis:

    The first step was to assess the existing maintenance practices followed by ABC Manufacturing. This involved reviewing the maintenance records and conducting interviews with maintenance personnel and plant operators. The analysis revealed that the company followed a purely reactive maintenance strategy, i.e., repairs were made only after an instrument failed. Additionally, there was no centralized system for tracking maintenance activities, leading to delays and inefficiencies.

    2. Identification of Critical Instruments:

    Next, we identified the critical field instruments that were most prone to failures based on historical data and expert opinion. These instruments were classified into three categories: critical, high priority, and low priority. Critical instruments were those whose failure had the highest impact on production, quality, or safety, while high-priority instruments had a moderate impact, and low-priority instruments had a minimal impact.

    3. Development of Preventative Maintenance Procedures:

    Based on the criticality of the instruments, we developed preventative maintenance procedures that outlined the tasks to be performed at regular intervals to ensure optimal performance. These procedures included visual inspections, calibrations, replacements, and cleaning. The frequency and type of maintenance activities were customized for each instrument based on its criticality, environment, and usage.

    4. Implementation Support:

    To ensure the smooth implementation of the preventative maintenance procedures, our consulting team provided training to the maintenance personnel and plant operators on the new processes and guidelines. We also developed a digital system for tracking and recording maintenance activities, which enabled real-time monitoring and reporting.


    Our consulting engagement with ABC Manufacturing resulted in the following deliverables:

    1. Comprehensive report on the current maintenance practices, including challenges and recommendations for improvement.

    2. List of critical field instruments and their classification into three categories: critical, high priority, and low priority.

    3. Preventative maintenance procedures for all critical and high-priority instruments, including recommended frequency and tasks.

    4. Training materials and sessions for maintenance personnel and plant operators on the newly developed procedures.

    5. Digital system for tracking and recording maintenance activities.

    Implementation Challenges:

    There were several challenges faced during the implementation phase, including resistance to change, limited resources, and organizational silos. Some maintenance personnel were reluctant to adopt the new procedures as they were used to the reactive approach. Additionally, the company had limited resources, both in terms of personnel and technology, which made it challenging to implement the new system and procedures effectively. Moreover, there were organizational silos between maintenance and operations teams, resulting in communication gaps and delays in coordination.

    KPIs and Management Considerations:

    The success of the preventative maintenance procedures was measured using the following key performance indicators (KPIs):

    1. Mean Time to Repair (MTTR): This KPI measures the average time taken to repair an instrument after it has failed. A decrease in MTTR indicates the effectiveness of the preventative maintenance procedures.

    2. Maintenance Costs: The cost of implementing the new procedures and the cost of repairs and replacements were tracked to measure the impact on maintenance costs.

    3. Equipment Availability: The percentage of time the critical instruments were available for use was monitored to track the effectiveness of the preventative maintenance procedures.

    To ensure the sustainability and continuous improvement of the preventative maintenance procedures, the following management considerations were recommended:

    1. Regular review of the procedures: The procedures should be reviewed periodically to identify any areas for improvement and make necessary updates.

    2. Ongoing training and awareness: Training should be provided to new personnel, and refresher sessions should be conducted for existing personnel to ensure the proper implementation of the procedures.

    3. Integration with other systems: The digital system for tracking maintenance activities should be integrated with other systems, such as inventory management, to enable better coordination and optimization of resources.


    In conclusion, our consulting engagement with ABC Manufacturing enabled the development and implementation of preventative maintenance procedures for all field instrumentation. This resulted in significant improvements in MTTR, reduction in maintenance costs, and increased equipment availability. It also helped the company move from a reactive maintenance approach to a proactive one, leading to improved operational efficiency and reduced risks. The success of this project highlights the importance of preventative maintenance procedures in ensuring the optimal performance of critical equipment in manufacturing environments.

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