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European Maintenance Std.
Benchmarking
Maintenance Models
- RCM
- CCFI
- Integration Model - TPM
Development of Maintenance
Compiled By:Rudolf Schenker Pr.Tech.Eng., Reg.Eng.TechMTECH.- Mech. Engineering
© All Rights Reserved 2003
Methods toOptimization
- Implementation
International Maintenance
Standards
European Maintenance Std.
Benchmarking
Maintenance Models
- RCM
- CCFI
- Integration Model - TPM
Development of Maintenance
Compiled By:Rudolf Schenker Pr.Tech.Eng., Reg.Eng.TechMTECH.- Mech. Engineering
© All Rights Reserved 2003
Methods toOptimization
- Implementation
Maintenance: according to EN 13 306:2001
MaintenanceMaintenance
Preventive Maintenance
CorrectiveMaintenance
Condition BasedMaintenance
PredictiveMaintenance
Scheduled/Planned (cycle), continuous or per Order
Forced/UnplannedDeferred or Immediate
Before a detected fault
After a detected fault
European Maintenance Std.
Benchmarking
Maintenance Models
- RCM
- CCFI
- Integration Model - TPM
Development of Maintenance
Compiled By:Rudolf Schenker Pr.Tech.Eng., Reg.Eng.TechMTECH.- Mech. Engineering
© All Rights Reserved 2003
Methods toOptimization
- Implementation
Maintenance Types
immediate reporting,find, control help
planned Inspection,Reliableand correctexecution
j.i.t. andfactual warnings
Inspection order (Report to Operator or Maintenance/Inspection Center)Support during Inspection execution (Guidance, Photos, Documentantion)
tran
spar
ent
thro
ugho
ut t
he
Org
aniz
atio
n of
all
Mai
nten
ance
Pro
cess
es Diagnose the E-Equipment
(Loose Connection...)
All w
ork
stat
ions
Supp
ort u
sing
all M
ater
ial &
Equ
ipm
ent
(Aud
io, V
ideo
- wi
rele
ss, w
eb) Diagnose the Process
(Limit switch not made...)
Monitoring the E-Equipment (Wear/Life expectancy....)
Monitoring the Mechanics (Bearings, Gearboxes, Blowers, Compressors...)
Corrective Maintenance
Preventive Maintenance
Predictive Maintenance
European Maintenance Std.
Benchmarking
Maintenance Models
- RCM
- CCFI
- Integration Model - TPM
Development of Maintenance
Compiled By:Rudolf Schenker Pr.Tech.Eng., Reg.Eng.TechMTECH.- Mech. Engineering
© All Rights Reserved 2003
Methods toOptimization
- Implementation
Maintenance Types and its Results
Time and/or Life Cycle driven (km, work hours, poor Quality)
Tran
spar
ency
thr
ough
out
the
Org
aniz
atio
n of
all
Mai
nten
ance
Pro
cess
esUs
ing
a CM
MS.
Reacted too late, i.e. if a Error occurred
e.g. Breakage, Leakage, BreakdownExtreme high Resulting Costs
Just-in-Time-MaintenanceIndicators, CBM
Optimal Maintenance Timing , planned inline
with the Production !
Corrective Maintenance
Preventive Maintenance
Predictive Maintenance
Maintenance too often / thus too expensive
immediate reporting,find, control help
planned Inspection,Reliableand correctexecution
j.i.t. andfactual warnings
European Maintenance Std.
Benchmarking
Maintenance Models
- RCM
- CCFI
- Integration Model - TPM
Development of Maintenance
Compiled By:Rudolf Schenker Pr.Tech.Eng., Reg.Eng.TechMTECH.- Mech. Engineering
© All Rights Reserved 2003
Methods toOptimization
- Implementation
If effective Maintenance Strategies are to be implemented, then the distribution of Maintenance Techniques should be according to the following guidelines:
33 % of the damage caused; to be countered by CBM. (detective maintenance)25% of the damage caused; to combat with Predictive Maintenance5% of the damage caused; to be avoided with Preventive Maintenance33% of the damage caused due to “run to failure”4% of the damage caused due to Design
detective
predictivepreventive
run to failure
redesign
Experiences: Distribution of the Strategic Measures
European Maintenance Std.
Benchmarking
Maintenance Models
- RCM
- CCFI
- Integration Model - TPM
Development of Maintenance
Compiled By:Rudolf Schenker Pr.Tech.Eng., Reg.Eng.TechMTECH.- Mech. Engineering
© All Rights Reserved 2003
Methods toOptimization
- Implementation
Time Concepts: Equipment Availability vs. Demand
Up StateDown State
Idle State Standby State
Operating State
External Disable State
Non RequiredTime
Non RequiredTime
RequiredTime
RequiredTime
European Maintenance Std.
Benchmarking
Maintenance Models
- RCM
- CCFI
- Integration Model - TPM
Development of Maintenance
Compiled By:Rudolf Schenker Pr.Tech.Eng., Reg.Eng.TechMTECH.- Mech. Engineering
© All Rights Reserved 2003
Methods toOptimization
- Implementation
Time Intervals: according to EN 13 306:2001
Time Between Failure (TBF) FailureFailure
Downtime(DT) Up Time (UT)
CorrectiveMaintenance
Time(CMT)
IdleTime(IT)
StandbyTime(SBT)
External DisableTime (EDT)
PreventiveMaintenance
Time(PMT)
OperatingTime
BetweenFailure(OTBF)
MTTR MTTM
MTBFMTBR
MTTFMFT
European Maintenance Std.
Benchmarking
Maintenance Models
- RCM
- CCFI
- Integration Model - TPM
Development of Maintenance
Compiled By:Rudolf Schenker Pr.Tech.Eng., Reg.Eng.TechMTECH.- Mech. Engineering
© All Rights Reserved 2003
Methods toOptimization
- Implementation
Time Concepts: according to DIN 8743
Effective Working Time
Downtime due to Machine
Downtime due to other
Inspection Time
Feed Time
Ancillary Time
Effective Working Time
Overall Working Time
Operating Time
Machine Operating Time
Effective Working Time Total Working time which the packaging machine is operating without breakdown.
Machine dependant downtime
Total time during which the packaging machine is stopped due to faults caused by the machine itself.
Machine in-dependant downtime
Total time during which the packaging machine is stopped due to faults caused by other reasons that the machine itself.
Inspection Time Time required for inspection and measurements.
Ancillary Time Total time where the machine is at standstill due to set-up, format change-over, servicing and cleaning, starting and stopping
Operating Input Number of Blisters or Package output during operating time.
Effective Output Number of Blisters or Package output during overall working time.
Efficiency Ratio Ratio of effective output to set output (actual output/set output)
European Maintenance Std.
Benchmarking
Maintenance Models
- RCM
- CCFI
- Integration Model - TPM
Development of Maintenance
Compiled By:Rudolf Schenker Pr.Tech.Eng., Reg.Eng.TechMTECH.- Mech. Engineering
© All Rights Reserved 2003
Methods toOptimization
- Implementation
Relationships: according to VDI 2246
Production Equipment
Profitability, Environmental, Health & Safety
Reliability Availability
MaintainabilityImprove
Maintainability and/or
Reliability to improve
Availability.
Redundant Reliability
improvements, e.g. complex
Automation/Controls could
complicate the Maintainability.
Maintenance Effort
(Maintainability) will be
high if Reliability is
low.
European Maintenance Std.
Benchmarking
Maintenance Models
- RCM
- CCFI
- Integration Model - TPM
Development of Maintenance
Compiled By:Rudolf Schenker Pr.Tech.Eng., Reg.Eng.TechMTECH.- Mech. Engineering
© All Rights Reserved 2003
Methods toOptimization
- Implementation
Definitions: as per EN 13 306
Reliability: Ability of an item to perform a required function
under given conditions for a given time interval. (rs note: reliability is high (1) when the probability of failure is low))
Maintainability: Ability of an item under given conditions of use, to
be retained in, or restored to, a state in which it can perform a required function, when maintenance is performed under given conditions and using stated procedures and resources. (rs: maintainability is high (1) when maintenance/effort is high (1)
Availability: Ability of an item to be in a state to perform a
required function under given conditions at a given instant of time or during a given time interval, assuming that the required external resources are provided. (rs: Availability is high (1) when equip. is always available for production)
European Maintenance Std.
Benchmarking
Maintenance Models
- RCM
- CCFI
- Integration Model - TPM
Development of Maintenance
Compiled By:Rudolf Schenker Pr.Tech.Eng., Reg.Eng.TechMTECH.- Mech. Engineering
© All Rights Reserved 2003
Methods toOptimization
- Implementation
Wear Definitions: according to DIN 50 320
DIN 31 051: Wear Allowance…considering maintenance, wear is allowed to a state where the functional performance, based on defined operational conditions, is not affected.
European Maintenance Std.
Benchmarking
Maintenance Models
- RCM
- CCFI
- Integration Model - TPM
Development of Maintenance
Compiled By:Rudolf Schenker Pr.Tech.Eng., Reg.Eng.TechMTECH.- Mech. Engineering
© All Rights Reserved 2003
Methods toOptimization
- Implementation
Summary: International Maintenance Standards
DIN 31 051 Maintenance Definitions DIN 13 306 Maintenance Terms and Explanations
DIN 8743 Time Concepts SAE - JA1011 Evaluation Criteria for RCM Processes .
SAE - JA1012 A Guide to the Reliability-Centered Maintenance (RCM) Standard
VDI 2886 Benchmarking Design
VDI 2264 Relationships of Maintainability, Availability, Reliability
DIN 50 320 Maintenance; Wear Definitions EN DIN 32 736 Building Management - Work Areas VDMA 24 196 Commercial Business ManagementDIN ISO 10011 Quality Audit Techniques
European Maintenance Std.
Benchmarking
Maintenance Models
- RCM
- CCFI
- Integration Model - TPM
Development of Maintenance
Compiled By:Rudolf Schenker Pr.Tech.Eng., Reg.Eng.TechMTECH.- Mech. Engineering
© All Rights Reserved 2003
Methods toOptimization
- Implementation