Abstract
Equipment preventive maintenance is essential to build and maintain robust and diverse manufacturing facilities and to cover the demand in a reliable pattern. However, most firms face problems either in scheduling equipment shutdown time for preventive maintenance or booking maintenance resources. This paper presents the application of Criticality Analysis CA in a Pharmaceuticals company, where CA was used to asses one hundred and eighty-five utilities equipment's reliability and importance. Two major categories of factors were identified and customized by cross-functional teams; the severity on business and the probability of failure. For each category, different factors and evaluation scales were created. For the impact and severity on business, the study used eight different factors; safety/health, environment, alternative route/system, quality, Good Manufacturing Practices GMP's, production losses, maintenance costs, and utilization percentages. Whereas, life expectancy, failure frequency, and equipment condition are the factors selected for the probability of failure. Each machine has been evaluated with respect to the eleven indicators, and then a risk matrix was used to classify the equipment and set the priority levels. The results were used to reschedule the preventive maintenance accordingly. The rescheduled preventive maintenance plans show a massive reduction in the time and human resources required to complete the job. These plans will eventually improve maintenance effectiveness by maximizing reliability and availability for equipment and by reducing failures effects and causes, leading to proper utilization of resources.