BTKM 3523 Maintenance Technology and Asset Management

Introduction to

Maintenance Management Systems

Introduction to Maintenance Management Systems

Contents:

Maintenance Management Objectives. Maintenance Policies & Strategies. Maintenance Planning & Scheduling. Work Order System. Maintenance Cost Control. Spare Part Control.

Reliability Centered Maintenance

Total Productive Maintenance. Performance Keys Indicators.

Introduction to Maintenance Management Systems

References:

Maintenance Engineering Handbook - 5th Edition By Lindley R. Higgins, P.E. & Others McGraw-Hill, Inc. Computerized Maintenance Management System (2nd Edition) By: Terry Wireman Industrial Press, Inc.

Developing Performance Indicators for Managing Maintenance

By: Terry Wireman Industrial Press, Inc.

Internet Articles & Resources

Maintenance Management Objectives

Chapter I

Introduction

Industry today is in a fight to survive. Competition is found not

only on a domestic level, but also on international levels. In an effort to survive, all forms of production analysis, product reviews, and material

reviews are made and periodically checked. Statistical process control is

only one of the new methods used to reduce operational costs. However, one area many industries are now turning their attention toward is the

maintenance function.

Introduction (Cont.)
Cost reduction in maintenance does not necessarily mean a reduction in service or in the quality of service. It means a better control of the maintenance organization and the related areas. To properly control the maintenance of any facility, information is required to analyze what is occurring. Manually, this requires a tremendous amount of effort and time. In recognition of this, many of the progressive companies are developing and using computer programs geared toward control of the maintenance organization. These systems are often referred to as computerized maintenance management systems (CMMS).

What is Maintenance?

Maintenance - any activity carried out on an asset in order to ensure that the asset continues to perform its intended functions, or to repair the equipment. Note that modifications are not maintenance, even though they may be carried out by maintenance personnel.

What is Maintenance?
Maintenance is war. Your enemies are the triumvirate of breakdown, deterioration, and all types of unplanned events. Your soldiers are the maintenance department and as many civilians as you can recruit. The civilians you protect are production workers, office workers, drivers, and all the other users of your organizations assets.
Joel Levitt

 Maintenance is the work undertaken in order to keep or restore a facility to an acceptable standard level.
Work undertaken All activities (information, analysis, repair, etc.)

What is Maintenance?

To keep To restore Facility

Planned maintenance (Preventive, Predictive and proactive) policy for critical equipment Unplanned maintenance (Corrective or run to failure policy for non-critical equipment System level (equipment, unit, plant)

Acceptable standard Acceptable level at certain working condition (HSE, level working hours, etc.)

What is Maintenance?
Keeping equipment's available, reliable and cost optimized

Asset ?
Asset - unlike in the accounting definition, in maintenance this is commonly taken to be any item of physical plant or equipment It is the basic unit of maintenance.

Asset Management ?
Asset Management - the systematic planning and control of a physical resource throughout its life. This may include the specification, design, and construction of the asset, its operation, maintenance and modification while in use, and its disposal when no longer required.

Maintenance Function ?
The maintenance department has a more involved list of functions or responsibilities. These can be grouped into five main areas:Maintenance of existing equipment. Equipment inspection and services. Equipment installation. Maintenance storekeeping. Craft administration.

1. 2. 3. 4. 5.

Maintenance Function 1. Maintenance of Existing Equipment

Maintaining existing equipment is the basic reason for the department. The maintenance group will make repairs to the production equipment as quickly and economically as possible. They should be able to anticipate repairs, based on previous experi-ence with the equipment.

To prevent rapid wear of the equip-ment, the group should utilize costeffective preventive maintenance programs.
To perform these tasks as efficiently and cost effectively as possible requires the utilization of a trained workforce and the use of modern tools and maintenance methods that are available. However, performing all of the above tasks depends on one im-portant item accurate record keeping. Without accurate re-cords, it will not be possible to complete the assigned tasks in a timely and cost-effective manner.

Maintenance Function ? 2. Equipment Inspections and Service

This task will require the engineer or manufacturer to determine the proper lubricant for the equipment. In addition to the type of lubricant, the proper amount and time intervals of application of the lubricant are necessary. The inspections are required to ensure that the equipment is in safe operating condition and is being serviced in a timely manner. Some installations will require that the operational personnel do some routine lubrication and servicing. Even where this is a common practice, the maintenance department should oversee the completion of the tasks.

3. Equipment Installation

Maintenance Function ?

This responsibility varies from industry to industry and depends on the size of the installation and the maintenance workforce. Some industrial facilities that require constant equipment changeover may have an installation department. When large installation projects occur in some industries without the necessary workforce, outside contractors are used to supply the needed manpower.

Maintenance Function ?

4. Maintenance Storekeeping
This responsibility of the maintenance group involves the receiving and distribution of the spares necessary for the repair and upkeep of the plant equipment. There are several important tasks involved in this responsibility. The first is recording the necessary spares for each piece of equipment. With all of the spares recorded, the maintenance group has the responsibility of setting the inventory level for each part. As the spares are used, the replacements will have to be ordered. The ordering process is important to prevent material outages in the stores. Material outages could result in production delays, if equipment breakdowns occur and no replacement parts are available. Keeping the stores inventory level as low as possible will prevent tying up capital investments in spares.

Maintenance Function ?
5. Craft Administration
This is the responsibility of controlling the manpower used by the maintenance department. The most cost-effective way of determining the size of the workforce is the work in the maintenance backlog. By looking in the backlog, the number of employees for each craft area can easily be determined. As programs are changed and equipment is added or deleted from a department, the workforce can be adjusted as necessary. The responsibility for providing the necessary tools and supplies for the crafts is also included in this area.

Maintenance Objectives
1. To keep the maintenance cost per production item produced as low as possible. 2. To keep the quality of the product very high. 3. To keep the downtime for critical equipment as low as possible. 4. To keep maintenance cost as low as possible for non-critical equipment. 5. To provide and maintain adequate facilities. 6. To provide effective and trained supervision.

What is Management?
Art of doing what is possible out of what is available Sharing in overheads that leads to unity of goal Coordination of different tones in a harmony Guaranty of never being caught in a surprise condition

Maintenance Management
Maintenance Management is defined as the organization of maintenance within an agreed policy. Maintenance Policy is a statement of principle used to achieve maintenance objectives and guide Maintenance Management decision making.

In general the following Philosophy items represent (Policy) the main Maintenance aspects of maintenance philosophy or policy:

Maintenance organization i.e., centralized versus decentralized maintenance. In-house versus outside contracting maintenance. Preventive versus predictive maintenance. Repair versus replacement.

Types of Maintenance
Chapter 2

Maintenance Types (Strategies)

Reactive Maintenance Preventive Maintenance Predictive Maintenance Proactive Maintenance

REACTIVE MAINTENANCE
A strategy which tells us that when a machine fails then it is time for maintenance to fix it where no routine maintenance tasks are performed on the equipment.

and then only after the equipment has suffered a failure. Also described as a Run-to-Failure strategy.

REACTIVE MAINTENANCE
Is generally the economic approach for equipment which causes no significant safety hazards or loss of revenue and suffers little consequential damage on breakdown. Ex: small pipe work leaks and non critical mechanical, electrical and instruments faults

REACTIVE MAINTENANCE
Limitations of reactive maintenance is that it cause unplanned downtime & production de-lays w/c results in revenue losses & extending the maintenance to work overtime to fix the equipment. Repairing the equipment after it fails usually creates the possibility of secondary damage w/c increase the maintenance costs

REACTIVE MAINTENANCE
Limitations of reactive maintenance is that it cause unplanned downtime & production de-lays w/c results in revenue losses & extending the maintenance to work overtime to fix the equipment. Repairing the equipment after it fails usually creates the possibility of secondary damage w/c increase the maintenance costs

PREVENTIVE MAINTENANCE
Preventive maintenance is the utilization of planned and coordinated inspections, adjustments, repairs and replacement needed in maintaining an equipment or plant. Its main objective is to detect any condition that may cause machine failure before such breakdown occurs. Thus, it make possible to plan and schedule maintenance work without interruption in production.

And, improve the availability of equipment

PREVENTIVE MAINTENANCE
A systematic and extensive inspection of each item of equipment (or the crictical parts) is made at predetermined intervals. Should only be applied where the probable cost of lost revenue and/ or consequential damage resulting from failure scientifically exceeds the cost of such preventive maintenance work and associated down time. To avoid serious breakdowns, the preventive mode of maintenance is usually implemented in complex plants

PREVENTIVE MAINTENANCE
A systematic and extensive inspection of each item of equipment (or the crictical parts) is made at predetermined intervals. Preventive maintenance is costly because during inspection all deteriorated parts/components are replaced Should only be applied where the probable cost of lost revenue and/ or consequential damage resulting from failure scientifically exceeds the cost of such preventive maintenance work and associated down time.

PREVENTIVE MAINTENANCE
What are the main activities of preventive maintenance? Assignment: In a group of 3, find the activities of preventive maintenance. List and explain the activities of preventive maintenance. Prepare a presentation slides and explain to your class . Due: Next week: 30.9.13. Submission: hardcopy of the slides.

Maintenance Planning & Scheduling

Availability of information Trend tracking Prevention of sudden failure Optimizing equipment performance Managing the manpower Minimizing the inventory stock

Necessity and Benefit of Applying PM Program

Predictive Maintenance (PDM)

An equipment maintenance strategy based on measuring the condition of equipment in order to assess whether it will fail during some future period, and then taking appropriate action to avoid the consequences of that failure. The condition of equipment could be monitored using Condition Monitoring, Statistical Process Control techniques, by monitoring equipment performance, or through the use of the Human Senses.. Condition-based maintenance

Predictive Maintenance (PDM)

Was introduced around 1970 to improve the defect of over maintenance that preventive maintenance inherently held. Includes corrosion measurement activities by using ultrasonic test, radiograph test, Corroso Meter, etc, that were called On Stream Inspection (OSI), as well as rotating machinery diagnosis activities using vibration and noise analysis, etc. Predictive maintenance indicates generally only the diagnosis, and if deterioration are detected in diagnosis and consequently overhaul is requested the execution of repair will be arranged.

Predictive Maintenance (PDM)

Takes into consideration the actual condition of equipment when deciding whether maintenance is necessary Required regular monitoring of critical equipment and predicts problems before they occur. CBM condition based maintenance policy is most suited to high capital cost equipment and complex replaceable items

Predictive Maintenance (PDM)

Since failures can be predicted, the user can establish a prognosis for the fault. The most important information here is to determine how rapidly the fault or failure is progressing, when it is likely to stop the machine from fulfilling its design function and what are the consequences of the failure itself

Predictive Maintenance (PDM)

Advantages of using CBM: Safety minimize injury and fatal accidents Availability increase availability means increase the output Downtime avoide unschedule breakdowns and reduction in total downtime of equipment

Predictive Maintenance (PDM)

Two categories of CBM: On-line monitoring which can be carried out during the operation of the machine without stopping it Off-line monitoring which can only be carried out after shutdown of the machine For example: in a gas turbine engine, the temperature of the burner can be monitored but the bearings can only be inspected after the engine has been shut down.

PROACTIVE MAINTENANCE
Proactive Maintenance is about analyzing why failures occur so that its recurrence is finally eliminated, and thereby extending the life of the part or component Proactive Maintenance is when maintenance or a group of cross-functional team analyzes the failure with analytical techniques such as Root Cause Failure Analysis, FMEA, Kepner Tregoe, P-M Analysis, FaultTree Analysis etc. are used to better understand why the failure occurred in the first place.

PROACTIVE MAINTENANCE
In Preventive Maintenance we replace the part that we think is in the process of wearing out. Our thinking is that replacing the part will bring the equipment back to its original condition, we have not taken into account the need to analyze further why a certain part keeps on failing.

WORLD CLASS MAINTENANCE EXCELLENCE :

- The best maintenance strategy is being able to apply the different tasks simultaneously with the aid of a Decision Diagram or an Algorithm
Majority of industries confined their maintenance tasks to these options

Maintenance Decision

Reactive Maintenance

Preventive Maintenance

Predictive Maintenance

Proactive Maintenance

10 - 15 %
Minimal damage in w/c maintenance and the operations can tolerate

20 - 30 %
When parts have a specific age and they survive to reach this

40 - 50 %
Best used for parts with potential failure condition

10 - 20 %
When there is a need for a failure to be analyzed

PROACTIVE MAINTENANCE
Proactive Maintenance is about analyzing why failures occur so that its recurrence is finally eliminated, and thereby extending the life of the part or component Proactive Maintenance is when maintenance or a group of cross-functional team analyzes the failure with analytical techniques such as Root Cause Failure Analysis, FMEA, Kepner Tregoe, P-M Analysis, FaultTree Analysis etc. are used to better understand why the failure occurred in the first place.