MAINTENANCE CONCEPTS

“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? There are four basic Maintenance Concepts: UNPLANNED Maintenance A conscious decision to do nothing until failure PREVENTIVE Maintenance Change parts and fluids on a schedule PREDICTIVE Maintenance Anticipate rather than react Hybrid Best of preventive and predictive Extreme To High Costs High To Moderate Costs Good Cost Reduction Most Efficient Cost Reduction • What are your short-term goals? • What tools will you use? 3. How and when will you get there?

• Where are you now? • Do you have a plan? • What is your current cost? • Is the plan realistic and doable? • Do you have vendor support and help?

HOW WILL YOU MEASURE SUCCESS?
How you measure success can be based upon what constitutes success in your program. The possibility of real reduction in the cost for maintenance (parts and labor), energy, downtime, and scrap. Another advantage, could be improvements or increases 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 Cost • Overtime • Lost production • Catastrophic repair cost • High energy cost • High inventory parts Short Component Life • Minor problems progress to failure • Repetitive repairs Reactive Maintenance • Fix it when it breaks • No time for failure analysis • No historical data to learn from

©2005
E-mail: information@bluemoonsystems.com • 1249 Oliver Street • Bowling Green, KY 42104

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PREVENTIVE Maintenance Maintenance based on time, distance traveled, or mile intervals Moderate High Maintenance Cost • Over or under maintained equipment • Inspections may create more problems than are corrected • Energy cost are still high • Repetitive repairs • Production loss Short Component Life • Repair start-up problem • Unlimited historical information Reactive Maintenance • UNPLANNED Maintenance • No root cause analysis • Exposure to external supply and storage problems

THE ISSUE
“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 feel that PM is cost effective. PREDICTIVE Maintenance Condition based maintenance Reduced Maintenance Costs • Less overtime • Significantly reduced repetitive repairs • Increased production • Decreased energy cost • 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 successful realization of their goals. Increased Component Life Proactive Reliability Assessment • Minor problems corrected early • Analysis and anticipate rather then react and repair • Historical data encourages • Trending and developing unique purchase of equipment component action • Designed for real life application of that equipment

©2005
E-mail: information@bluemoonsystems.com • 1249 Oliver Street • Bowling Green, KY 42104

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OR HYBRID? “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 component failures. Scheduling is usually based on one or more of the following: • Warranty requirements • Maintenance experience • Advice of fluid and filter manufacturers

PREVENTIVE, PREDICTIVE

Overall it has been a successful practice. But it is not necessarily the most cost effective practice. Failures still occur, 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 components proven needs, rather than a recurring schedule. Condition is usually determined by a combination of non-invasive techniques; 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. A decision is then made to take action or not. In all cases minor problems can be corrected before they cause a major problem. You can call it TRUE PREVENTIVE maintenance. But, since it involves the process of analysis and anticipate, it is in fact PREDICTIVE maintenance. In some cases once an abnormal trend develops probabilities can be put in 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.

©2005
E-mail: information@bluemoonsystems.com • 1249 Oliver Street • Bowling Green, KY 42104

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DEVELOP A PLAN • EXECUTE THE PLAN TEST AND CONTINUALLY REASSESS THE PLAN
Identify current maintenance status and detailed cost Develop short and long range goals, with a time schedule Select the maintenance path required to meet your goals • PREVENTIVE Maintenance PM • PREDICTIVE Maintenance PDM • PROACTIVE Maintenance Hybrid of Both Determine manpower and training requirements Determine which tools are required to meet your goals • Applicable hardware and software • Root cause analysis and documentation process • Fluid and wear particle analysis

©2005
E-mail: information@bluemoonsystems.com • 1249 Oliver Street • Bowling Green, KY 42104

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