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Maintenance Concept

Maintenance Concept

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Published by somjit saranai

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Published by: somjit saranai on Jul 15, 2009
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05/03/2013

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 © 2005
E-mail: information@bluemoonsystems.com  1249 Oliver Street • Bowling Green, KY 42104E-mail: information@bluemoonsystems.com • 1249 Oliver Street • Bowling Green, KY 42104
1
M
AINTENANCE
C
ONCEPTS
“Do You Know The Real Costs Of The Maintenance Category You Are Currently Using?” 
The path to equipment reliability requires:
1.
Understanding where you are now?
2.
Where do you want to be?
3.
How and when will you get there?
There are four basic Maintenance Concepts:UNPLANNED
Maintenance
A conscious decision to do nothing until failure
Extreme To High CostsPREVENTIVE
Maintenance
Change parts and fluids on a schedule
High To Moderate CostsPREDICTIVE
Maintenance
Anticipate rather than react
Good Cost ReductionHybrid
Best of preventive and predictive
Most Efficient Cost Reduction
Where are you now?
Do you have a plan?
What are your short-term goals?
What is your current cost?
Is the plan realistic and doable?
What tools will you use?
Do you have vendor support and help?
H
OW
 
W
ILL
 
Y
OU
 
M
EASURE
S
UCCESS
?
How you measure success can be based upon what constitutes success in your program. The possibility of real reduction inthe cost for maintenance (parts and labor), energy, downtime, and scrap. Another advantage, could be improvements orincreases in production time, equipment availability, safety, and/or overall fluid life.
“Applying Maximum Equipment Life And Reliability As The Ultimate Goal” 
UNPLANNED
Maintenance
A conscious decision to do nothing until failure!
Very High Maintenance CostShort Component LifeReactive Maintenance
Overtime
Minor problems progress to failure
Fix it when it breaks
Lost production
Repetitive repairs
No time for failure analysis
Catastrophic repair cost
No historical data to learn from
High energy cost
High inventory parts
 
 © 2005
E-mail: information@bluemoonsystems.com • 1249 Oliver Street • Bowling Green, KY 42104E-mail: information@bluemoonsystems.com • 1249 Oliver Street • Bowling Green, KY 42104
2
PREVENTIVE
Maintenance
Maintenance based on time, distance traveled, or mile intervals
Moderate High Maintenance CostShort Component LifeReactive Maintenance
Over or under maintained equipment
Repair start-up problem
UNPLANNED Maintenance
Inspections may create more
Unlimited historical information
No root cause analysisproblems than are corrected
Exposure to external supplyand storage problems
Energy cost are still high
Repetitive repairs
Production loss
T
HE
I
SSUE
“Do You Know That Every Component Is Unique?” 
Do you believe that every component is unique, or that all like components will develop the same problems at the same time?If you believe that all components are unique, then you will probably recognize that this maintenance concept is not cost effective.But if you believe that all like components develop the same problems at about the same time, then most likely you will feelthat PM is cost effective.
PREDICTIVE
Maintenance
Condition based maintenance
Reduced Maintenance CostsIncreased Component LifeProactive Reliability Assessment
Less overtime
Minor problems corrected early
Analysis and anticipate ratherthen react and repair
Significantly reduced repetitive
Historical data encourages
Trending and developing uniquerepairspurchase of equipmentcomponent action
Increased production
Decreased energy cost
Designed for real life applicationof that equipment
Decreased repair cost
Proactive reliability assessment techniques rely on technology, experience and common sense. That is why most companies are integrating the skills of maintenance, engineering, and tribology into their management practices. If they further enlist the skills of their vendor’s knowledge and experience, they maximize the chances for successfulrealization of their goals.
 
 © 2005
E-mail: information@bluemoonsystems.com • 1249 Oliver Street • Bowling Green, KY 42104E-mail: information@bluemoonsystems.com • 1249 Oliver Street • Bowling Green, KY 42104
3
P
REVENTIVE
,
P
REDICTIVE
 
OR
 
H
YBRID
?
“Do You Know The Real Cost Or Savings Of The Maintenance Strategy You Are Currently Using?” 
PREVENTIVE
Maintenance
PM is based on time or mileage intervals to perform specific maintenance tasks and fluid changes, adjustment,inspections, and overhauls. It is preventive in that it presumes that these actions will prevent major componentfailures.Scheduling is usually based on one or more of the following:
Warranty requirements
Maintenance experience
Advice of fluid and filter manufacturersOverall it has been a successful practice. But it is not necessarily the most cost effective practice. Failures stilloccur, maximum reliability and life expectancy may be sacrificed by PM programs.One of the most important steps in going from PM to PDM or Hybrid is to develop a root cause analysis process.You can’t develop a program to extend component life unless you know what shortens equipment life.
“Which Maintenance Concept Would Be Most Cost Effective In Your Operation?” 
PREDICTIVE
Maintenance
PDM is condition based maintenance. Maintenance is still scheduled, but based upon the individual componentsproven needs, rather than a recurring schedule. Condition is usually determined by a combination of non-invasivetechniques; oil analysis, vibration, electronic system testing, operational data recording (temperature, speed load,working time verses idle time.) The data is evaluated in terms of trends, and or deviation from normal trends. Adecision is then made to take action or not. In all cases minor problems can be corrected before they cause a majorproblem.
You can call it TRUE PREVENTIVE maintenance
. But, since it involves the process of analysis and antici-pate, it is in fact PREDICTIVE maintenance.
 
In some cases once an abnormal trend develops probabilities can be putin place that will pinpoint a time when action will have to be taken.
PROACTIVE
Maintenance
Hybrid best of Preventive and Predictive maintenance
This combines the best of both PM and PDM program. It is what works best from each program for your  program...The best and most cost effective way for your maintenance program to work.

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