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COURSETITLE

MAINTENANCE&MAINTENANCESTRATEGIES

th

nd

InstructorIMRANSHAUKAT

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Old Concept: Preserving Physical Asset ew oncept: reserv ng unct on o sset

All technical, administrative and supervisory actions

combined together, intended to retain an item in, orrestore it to, a state in which it can perform a required

function. Or

It is a set of or anised activities that are carried out inorder to keep an item in its best operational condition

with minimum cost ac uired.

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SessionI

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a n enance s ory

re- or ar , ma n enance cons ere as an

added cost to the plant as it results in no increase ine va ue o n s e pro uc

So maintenance was only fixing the unit when it

breaks being the cheapest alternative After World War II other types of maintenance were

developed which were much cheaper such as

preventive maintenance At this time it was classified as a function of the

roduction s stem

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D

-Increased awareness of:

-Environment

-Safety

Preventivemaintenance

developed.

evelopm

Mainten

- ua y

-Need for reliable equipment.

-Reduction in costs.

breaks

ntof

nce

PostWorldWarIIPreWorldWarII 1980Onwards

Time

MaintenanceHistory

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Presently increased awareness of environment,sa ety, qua ty o pro uct an serv ces ma esmaintenance one of the most important functions

.

Competitive Companies are in continuous need of a

compete in this global village.

,cost and high efficiency calls for best maintenance

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Maintenance Engineering /management is most

important part of the plant Engineering ( biggestforce for productivity) Preserving physical asset

/function of asset

Preserving inherent reliability/ built in capacityTo reduce the business risk

To increase availability, reliability and asset

To protect environment and increase safety

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Maintenance objectives should be consistent with and

subordinate to production/operations goals andcompanys strategic plans.

The relation bet een maintenance ob ecti es and

production goals is reflected in the action of keepingroduction lant machines and facilities in the best

possible condition.

availability at the lowest cost and at the highest

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Optimising resources utilisatione uc ng own me

Improving spares stock control

Improving equipment efficiency and reducing scraprate

Minimising energy usage

Providing reliable cost and budgetary control

en y ng an mp emen ng cos re uc ons7/22/2010 9


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Maintain Plant & Equipment at its max efficiency

reducing down time & ensuring safety. Minimizing rate of deterioration at optimum cost.

replacement, specifications preparation, equipmentselection erection & commissionin

Standardization of spares and consumables, in

,

Maintaining utilities

Running of workshop & fabrication shop facilities7/22/2010 10


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PLANT

A

I

N

Reduce Downtime

ax m s ng ro uc on

Minimising Energy Usage

EN

A

Improving Equipment

Efficiency

Improving Inventory Control

Optimising Useful Life of

Equipment

Providing Budgetary Control

C

EImplementing Cost Reduction

Optimising Resources

Utilisation

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Besides plant availability and cost optimization

maintenance effects all as ects of businesseffectiveness and risk:

Environmental Integrity

Energy Efficiency

Product QualityCustomer Care

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v e nto two categor es- as c unct ons o

wise) & Composite function as c unct ons

Replace

RepairOverhaul

Rebuild/ Renovate/Recondition

Service Ins ect Test Ad ust Ali n Calibrate &install.

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ro ec ng ruc ures an an s

Reducing Down Time and Increase Availability

on ro ng an rec ng a or

Economy in the Maintenance Department

ax m z ng za on o va a e esources Ensuring Safety & Reducing Environmental Pollution

a n enance u ge repara on

Waste Reduction and Waste Recovery

mprov ng ec n ca ommun ca on

Training of Maintenance Personnel

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SessionII

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.

Economic input ( How Efficiently) -Output.

Down time due to maintenance.

Inventory Cost (Spares, tools, instruments,infrastructure)

Equipment condition

The above converted into metrics and kept as abase value for comparison.

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On going process of building and sustaining

relationship by assessing, anticipating and fulfillingstated and implied needs.

Extent to which products, services, processes and

inter relationship are free from defects, constraints,and items which did not add value to customers and

the commodity confirms the standard specified.

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Reliability:

Ability of a product to perform its intendedfunctions up to the intended duration.

Reliability Engineering. Covers all aspects of a

, ,

production process and practical lifetime use with

.

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Higher Revenue due to less or no interruptions

eputat on o t e company

Customer Satisfaction and requirement

Life time cycle cost

Less work for the Maintenance Team

g ora e

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e a y s av ng e equ pmen ava a e o run

as planned to meet customer demands at optimaleconom cs w n e p ys ca po en a o e

equipment.

Create a reliability mindset to improve reliabilityand execute world-class turnarounds and projects

that are completed safely, on time and on budget.

An improved reliability performance leads toimproved performance in the areas of process

safety, cost, energy and margin.

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.

A reliable plant is more energy efficient and resultsn ess unp anne re eases to t e env ronment.

A reliable plant produces more consistent product

quality. A reliable lant has the abilit to achieve hi her

utilization.

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re a e p an as ower reac ve ma n enance

costs along with higher utilization and lower unitcos s, ma ng more compe ve.

A reliable plant has the stability that makes margin

optimization possible, thereby realizing the fullpotential of the asset. Reliability mindset at all

levels of our organization.

A measure of your Companys reliability isreflected in the Unplanned Downtime performance:

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reliability led strategy. The core to this strategy

organization progress together in mitigating

,

would enable us to make production efficiently, and

organization

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e e a y anagemen ec on s ou e

tasked with coordinating all reliability relatedac v es, nc u ng commun ca ng e re a y

mindset via trainings, bulletins and organizing

ac v es suc as e e a y ay.

This would result in improved operational

efficiency, allowing us to achieve our desired

financial and operational performance.

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HumanReliability

Involvement,Interfaces

Process

Operational

reliabilityMaintainability

(Inbuiltreliability(Operate

in

designenvelop./SOP)

e uc ng

Reliability

(Maint. Strat,Effect.ExtendingMTBF)

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t s n erent c aracter st c o t e system es gn

pertaining to ease, accuracy, safety and system.

easures ta en ur ng es gn, eve opment,manufacture, installation stage of a manufactured

, - ,tools, logistics cost, skill level and facilities, etc.

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HFE

Modular DesignFuture Ex ansion or Modifications rovision

Standardize, Documents, and LabelUsing recognized national and company standards

an co esUse of commercial off the shelf components

Standard Labeling for identification, Displays

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a e wrong par s cu o . o our co ng

Accessibility is critical- Low reliability to be most

Exposure to environment to be considered

For less safer maintenance provisions to be kept

Hazards to be considered

Streamline testin calibration uick connectorslogical logistics, Prevent and Predict, etc

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Reliability and maintainability jointly effects

availability. A highly reliable equipment may fail rarely, but if its

maintainability is poor, it would take long time to

repair thus reducing availability. If maintainabilit is ood but reliabilit is oor it ma

fail very frequently

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Work

Work

SchedulingIdentification

Execution

RecordingAnalysis

KPIs Effectiveness Criteria


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KPIsEffectivenessCriteria1.MaintenanceLaborProductivity

2.MaintenanceDowntime

SystemApproach

b) PM&

PdM

related

repairs

3.RatioofMaint.toProdortotalplantPersonnel

4.MTBF&MTTFandothermeasures

Control1. Followups&Reviews

2. Meetings

5.Re a ty Ava a tyIn ces

6.MaintenanceExpenseBudgetOpexCapex

7.Capability&ConditionofEquipment

.

4. CompletionReports

5. Assessments&Surveys

6. Suggestions.

8. Othercontrolmeasures Outputs1. Availabilityofmachines

equipments&systemsfor

2. Reliabilityofmachines&

system

3. Increasedsafety&better

Functions

(Directjobs)Inputs

4. Lessinterruptions

5. Betterproductquality

6. Betterupkeepofmachines

1. Lubricating

2. Repairs

3. Cleaning

4. Adjustments

1.Maintenancepersonnel

2.Equipmentdetails

3.ProductionPlans

4.SOP&

SMP

7. Longlifeofequipment&

components

8. Lessoverallcost&better

5. Checking/

Inspections

6. Parts/module

replacement

5.PM,PdM&otherRepair

Plans

6.Overhauls

7.Spares&consumables

9. others7. Overhauls

8. Align,Balance

9. Test,Calibrate

10. Others

8.Tools,Tackles&Facilities;

etc7/22/2010 31


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SessionI

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.

Physical Asset- Maintenance Program or Strategy.

Household Equipment Simple &Car- Oil / Filter change Easy

-

Industrial Equipment Complex

Hundreds of Machines &

Millions of Rupees Expensive

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.

Balance Maintenance Cost against impact of Failure

Optimize asset life cycle cost against targetavailability and penalty of failure.

Plant ageing need different mix of tasks

a re uc on- go or e mos e ec ve as s

Owner wants reduced Maintenance Expenses Without

elevating risk or reducing reliability.

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Integrated information system for maint

strategy

Good Maintenance Strategy must have an integrated

information system for interacting with all concernedareas.

Many Maintenance Systems & Strategies are in use,

however selection must be based on: eed

Complexity and Reliability

ec no econom cs

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IntegratedInfo.

DrawingWork

Procedure(

O&M)

ys em or

Maintenance

Strategy

Purchasing

Problems,Defectsand

Fault Re orts

Strategy

,

Orders,etc

Inventory

WorkHistory Finance

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Evolution of Maintenance Strategies


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Evolution of Maintenance Strategies

FIRSTGENERATION

SECONDGENERATION

THIRDGENERATION FOURTH

GENERATION

Fitwhen

breaks

Scheduled

maintenance/

overhauls

Predictivemaintenance

Conditionmonitoring,

CBM

CBSetc

Under

development

moreuse

of

IT

Preventive

maintenance&

control

Designformaintenance

&Reliability (Designout

maintenance)

computer

modeling,expert

system&artificial

Lowtech

computerization

Hazardstudies

Hightech

computerization

intelligenceto

predict&

prevent

failures)

FMEA&FMECAetc

Expertsystems

Multiskilling&

teamwork

Proactivetolimited

extent

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MAINTENANCE

UNPLANNED

MAINTENANCE

(REACTIVE)

PLANNED

MAINTENANCE

(PROACTIVE)

BREAKDOWNEMERGENCY

CORRECTIVEPREDECTIVE PREVENTIVE IMPROVEMENT

REMEDIALDEFERREDCONDITION

BASED

STATISTICAL

BASED

DESIGN OUTENGINEERING

SERVICES

ROUTINERUNNING

WINDOW SHUTDOWNSHUTDOWN SHUTDOWN

Shutdown Maintenance

OPPORTU

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Types of Maintenance Strategies

Concept-B

ReactiveMaint

Breakdown&emergencyMaint

np anne orrect ve a nt

OpportunisticMaint

Maint

Strat /

sys Preventive

Maint

ScheduleFixed

TimeMaint

Planned

Predictive CBM

Proactive Maint Mix Strat. As Re

RoutineMaint

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Diagram To Select Appropriate Maintenance Strategy


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Detection

g pp p gy

offailure

expensivepredictable

2.Operateto

Failure

3.DesignoutMaint

Age

related

difficult Timetofailureunpredictable

.

2.DesignoutMaint

3.Fixed Time PM

failure

pattern Detection

offailure

Timetofailure

predictable1.CBM

2.Operateto

replaceableitemwith

not

expensiveTimetofailure

Failure

1.CBM

history. xe me

1.DesignoutMaintenancean om

failure

pattern

MTBF2.Correctivemaintenance followed

bydesignoutmaintenance

3. CBM

High

MTBF 1.Operate

to

Failure2.CBM7/22/2010 41

St t i t M t h M i t N d


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Strategies to Match Maintenance Needs

Equipment PeopleServiceCondition

EliminateDowntime Events

PredictRemote

Monitorin &

MRO Process

Management Build

Produceto Spec

Diagnostics

Instructor Led

NetworkServices

ategies

BudgetReduce

Downtim

reven Training

Self Paced

Agreements

Scheduled &anceSt

eDuration

Speed to

React

Training

-Services

M

ainten

ange oneSupport

Renewal Parts

Services


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Run to Failure Maintenance (RTF)

Preventive Maintenance (PM)

Corrective Maintenance (CM)

Improvement Maintenance (IM)

Predictive Maintenance (PDM)

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The required repair, replacement, or restore actionperformed on a machine or a facility after the

occurrence of a failure in order to bring this

machine or facility to at least its minimumacceptable condition.

.

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t s su v e nto two types:

Emergency maintenance: it is carried out as fastas possible in order to bring a failed machine or

facility to a safe and operationally efficient

condition. Breakdown maintenance: it is erformed after

the occurrence of an advanced considered failure

for which advanced rovision has been made inthe form of repair method, spares, materials,

labour and e ui ment.

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u u sa van ages:

1. Its activities are expensive in terms of both directand indirect cost.

2. Using this type of maintenance, the occurrence of afailure in a component can cause failures in othercomponen s n e same equ pmen , w c ea s olow production availability.

. s ac v es are very cu o p an an sc e u ein advance.

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s ype o ma n enance s use u n e o ow ngsituations:

1. The failure of a component in a system isunpre c a e.

2. The cost of performing run to failure maintenanceac v es s ower an per orm ng o er ac v esof other types of maintenance.

. e equ pmen a ure pr or y s oo ow n or er oinclude the activities of preventing it within the

.

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Breakdown/ Reactive Maintenance


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Breakdown/ Reactive Maintenance

Concept-B

Breakdown

Decisionwhat

todo?

. Breakdown

repair

YES

Checkforhelp InformRequest

for

help

&facilitiesNO

required

Re airwork

andothers

Help

&

facilities

order&

materialsDocumentation

arranged

Breakdown or Emergency Maintenance


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Breakdown or Emergency Maintenance

Concept-B.

Repair done after failure.

Keep running till it breaks May work in small plant, where:

Simple Equipment no specialist or special tool is

nee e

No major consequence due to loss of production or

further damage to other components

No Safety or Environmental Hazard

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.

Not appropriate for:

complex plants having large no. of machines.High reliability requirement because of revenue

Where failure can cause Safety or Environmental.

Where restart of plant may take longer time.

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-

, , ,restoration will be carried out after the occurrence

of a failure in order to eliminate the source of thisfailure or reduce the frequency of its occurrence.

In the British Standard 3811:1993 Glossary of terms,

the maintenance carried out after recognition and intended toput an item into a state in which it can perform a requiredfunction.

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types:

Remedial maintenance, which is a set of activitiesthat are erformed to eliminate the source of failure

without interrupting the continuity of theproduction process.

The way to carry out this type of corrective maintenance is

and replacing it with reconditioned item or transferring itsworkload to its redundancy.

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,maintenance activities that are not immediately

initiated after the occurrence of a failure but aredelayed in such a way that will not affect theproduction process.

Shutdown corrective maintenance, which is a set of

when the production line is in total stoppage

situation.

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the maximisation of the effectiveness of all critical

plant systems, the elimination of breakdowns, the,of the deviations from optimum operatingconditions.

The difference between corrective maintenance and preventive maintenance is that for the corrective

corrective action is taken. Corrective maintenance is different from run to

and regularly taken out to keep plants machinesand equipment in optimum operating condition.

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activities is by conducting four important steps:

1. Fault detection.

. .

3. Fault elimination.. .

taken such as adjusting, aligning, calibrating,reworking, removing, replacing or renovation.

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order to be carried out effectively:

1. Accurate identification of incipient problems.

.

the planners, the availability of well developedmaintenance database about standard time to repair,a comp ete repa r proce ures, an t e requ relabour skills, specific tools, parts and equipment.

. .4. Adequate time to repair.

. .

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New

E ui mentRequestfor

PMactivity

defined

Integrate

withexisting

systemPMApprovalOld

Development

ofPMaction

yes

Typeof

PM

activity

programif

any

Equipment

reliability

redefined

ans

NOFrequency

Recommendations

What EquipmentsProblems Resource

Requirement

Instructions

Wor

or ers

closedinPM

system

SystemPM

program

generates

PMwork

ordersgivenPMactivities

executeddocumentation

PMwor

order

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It is a set of activities that are performed on plant

e ui ment machiner and s stems before the

occurrence of a failure in order to protect them andto revent or eliminate an de radation in their

operating conditions.

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r t s tan ar : ossary o terms

defined preventive maintenance as:

the maintenance carried out at redetermined

intervals or according to prescribed criteria andintended to reduce the robabilit of failure or the

degradation of the functioning and the effects

limited.

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activities is to satisfy most of maintenance.

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maintenance:

The need for an adequate number of staff in themaintenance de artment in order to erform this

type of maintenance.

The right choice of production equipment andmachinery that is suitable for the working

this environment.

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e requ re s a qua ca ons an s s, w ccan be gained through training.

The support and commitment from executive

The ro er lannin and schedulin of PMprogramme.

The ability to properly apply the PM programme.


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their failure would cause serious production losses.

Its aim is to maintain machines and facilities insuch a condition that breakdowns and emer encrepairs are minimised.

Its activities include replacements, adjustments,major overhauls, inspections and lubrications.

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into different kinds according to the nature of its

activities:

Routine maintenance which includes thosemaintenance activities that are repetitive andperiodic in nature such as lubrication, cleaning, and

.

Running maintenance which includes those

machine or equipment is running and they representthose activities that are performed before the actualprevent ve ma ntenance act v t es ta e p ace.

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maintenance activities that are performed on a

machine or a facilit when an un lannedopportunity exists during the period of performingplanned maintenance activities to other machines or

.

Window maintenance which is a set of activities that

required for a definite period of time.

Shutdown reventive maintenance, which is a set of preventive maintenance activities that are carriedout when the production line is in total stoppage

.

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Habits of Highly Effective Maintenance


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Organizationse roac ve

Begin with end in the mind

First thing first

Seek Win/Win

Seek first to understand than to beunderstood

Synergize

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SessionI

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ge o prac ce u no nown

Predicting upcoming maintenance needs bymonitoring condition indicators

Now become important as:

Good and Cheap tools available

Awareness and acce tance of tools and techni ues

Increased cost of equipment downtime

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CBMS

Continuous

Lubrication master


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Continuous

online

monitoring

master

schedule

Lubricationmaster

scheduleOilchanging

joborders

Defects/

Com onents

Dailylubrication

joborders

Deviations

observed

Vibration

work tobe

lubricated Defectin

machineJobreport

monitoring

VibrationDocumentationVibration

analysis

Diagnosis

recor s

Maintenancejob

planning&

workorder

Executionof

jobs

Vibration

monitoring

Vibration

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Risk Analysis in RBM

ProbabilisticHigh

Quantitative complexity

andcost

effective

Riskanalysis

semiQuantitative

JudgmentalLowcost

Traditional

Prescriptive

effective

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SessionII

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Com arison of Maintenance Strate ies


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NO STRATEGY APPROACH SIGNIFICANCE&

TECHNIQUESNEEDED

HUMANBODY

PARALLEL

1 Breakdown

(reactive)

Fixitwhenbreak Largemaintenance

budget

Heartattackor

stroke

2 preventive Scheduled

maintenance

Periodiccomponent

replacement/repair

Bypassor

transplantsurgery

3 predictive Conditionbased

monitoring

Monitoringcondition

byvibration,

heat,

alignment,wear

Detectionofheart

diseaseusing

EKG

orultrasonics

e r setc

4 proactive Detectionof

sourcesoffailure

Monitoringand

correctionoffailing

Cholesteroland

bloodpressure

rootcauses monitoring

with

dietcontrol.

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Where equipment is in its lifecycle commonly effects

how a maintenance strategy is applied.

Maintenance starts with en ineerin !

Technology


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TPM

RCA

EAM

5S

5Zero

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Question

&

Answers

Session

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