A good starting point is to use signs and labels to identify preventive maintenance (PM) points and to provide basic cleaning, inspection and lubrication instructions.

Using visual devices to identify PM points and provide detailed instructions is especially important if your company has implemented an autonomous maintenance program. When responsibilities for routine care and inspection are transferred to equipment operators instead of trained maintenance professionals, it’s critical to clearly define their tasks and checkpoints.

Here are some examples:
 
• Lube labels. Improper lubrication, whether it’s too little or too much, can be a major cause of equipment failure. A simple lube label can save your company significant costs in motor repair and replacement.

 

• Color-coded markings. Apply color-coded markings to zerk fittings and grease guns to guard against using the wrong type of lubrication.

• Oil level indicators. Simplify oil management with oil level indicator visuals. Green and red striped labels placed behind the sight tube lets the operator easily detect when oil levels are too high or too low.

Preventive maintenance schedules and check sheets are other valuable visuals to have on your shop floor. These schedules show who needs to perform what task, and when the task should be completed.

Even when maintenance personnel retain control of PM activities, the growing number of new and relatively inexperienced technicians in the workforce increases the risk of errors and omissions.

As baby boomers retire-about 78 million of them will do so in the next 10 to 15 years-the coming shortage of skilled workers will significantly affect industry. One large, well-known manufacturer recently forecasted that by 2014, approximately 70 percent of its maintenance staff will have less than five years of relevant job experience.

In addition, maintenance workers must learn how to use a growing number of sophisticated predictive maintenance technologies, such as vibration analysis, ultrasound and thermal imaging. When performing predictive maintenance, it’s critical to take measurements at the same exact place each time. To ensure that the location for readings remains consistent-regardless of who conducts the inspection-you can use visual predictive maintenance targets.

When implementing predictive maintenance programs, reliability technicians often use inspection routes to streamline the process and maximize efficiency. However, one drawback to this approach is that the technician may not be familiar with every piece of equipment, and the correct readouts may vary across different machines.

Here are some examples:

• Gauge labels. Visual controls like gauge labels make it clear at a glance whether the temperature or pressure is within the normal operating range. In fact, these visuals make it so easy to detect abnormalities, that anyone walking by becomes a potential inspector, facilitating early detection of potential problems.

• Chain tension indicators. Visuals can help you detect when chain tension is too loose or advise when to replace the chain.

When restoring equipment to operation, visuals can ensure efficient and error-free setup.

Here are some examples:

• Control panel labels and alignment aides. Visuals such as control panel labels and alignment aids help to simplify machine settings and positioning for operators.

• Gear and shaft labels. Labeling the rotational direction on gears and shafts can help avoid costly setup errors that can damage or destroy motors and drive systems.