Operational and Maintenance

Management
Heavy Machinery Management
Contents
• Introduction
• Terminal competences
• Competences
• Criticality systems
• Fault-free life
• Maintenance based on use
• Predictive maintenance
• Analysis of censored data
• Spare parts management
• Bibliography
Introduction
• This unit presents models of criticality of
equipment, criticality of detentions and
failures, and of maintenance management
that allow to consolidate the concepts and
apply them to real situations whose
objective is to optimize the availability of
heavy machinery.
Terminal Competences

• Evaluate and contextualize the

maintenance plan provided by the
manufacturer, optimizing operating costs
and the availability of heavy equipment in
different production processes.
Competences
• Determine critical failures for critical and important
equipment of heavy machinery.
• Determine the fault-free time that a equipment, system
or part.
• Analyze the convenience of a maintenance based on the
use according to the reliability analysis.
• Analyze the advantages and disadvantages of applying
predictive maintenance on a part, system or equipment.
• Analyze the life data according to the actual working
conditions of the heavy machine.
• Determine and analyze the quantity of spare parts to
acquire and store according to the rotation.
 Criticality Systems
• Classify the equipment according to its importance in the
production system or in case of failure, according to the
possible damages or accidents that may suffer.

Operations

Maintenance Administration

Mb.u.
Mpd ó
Mc
Criticality Detentions

Define the
Determine the Control the
interval with
stops of the duration of each
which each stop
machinery stop
is presented

Determine the
Develop the
frequency of the
frequency and
presence of each
duration graph
stop

1
Frequency 
IS
 10

7
Maintainability
Duration (hrs)

0
0 1 2 3 4 5 6 7 8 9 10
Frequency (Stops/hrs)

Reliability
 Criticality Detention
Selection
Determine the
Determine the Determine the
total
stops of the unavailability of
consequence of
machinery each stop
each stop

Determine the Develop the

Calculate the
impact of each unavailability and
specific impact
stop impact graph

Im p  ( LP  AC ). F Sp Im p  UA . Im p
 10

7
Impact ($/hrs)

0
0 1 2 3 4 5 6 7 8 9 10
Unavailability (%)
Weibull Reliability Model

 t 
 
R (t )  e   

• β < 1, β = 1 y β > 1
• γ < 0, γ = 0 y γ > 0
• R(η) = 36.79%
Util Life
Middle Time Between
Interventions

MTBI  T P .RT P   T F .F T P 

If:
• MTBI: Middle Time Between Interventions
• TP: Proactive maintenance interval
• TF: Failure age
• R(TP): Proactive interval reliability
• F(TP): Proactive interval failure probability
• For  = 0
MTBI  / * DISTR.GAMMA((Tp / )^  ;1/ ;1;1) * EXP(GAMMA.LN(1/ ))

• For Tp < 
MTBI  Tp

• For Tp > 
MTBI    / * DISTR.GAMMA(((Tp -  ) /  )^  ;1/ ;1;1) * EXP(GAMMA.LN(1/ ))
Availability Projection
MTBI
AO    .F  
T P DP DC T P
If:
• AO: Availabitlity
• MTBI: Middle Time Between Interventions
• TP: Proactive maintenance interval
• DP: Proactive maintenance duration
• DC: Corrective maintenance duration
• F(TP): Proactive interval failure probability
Proactive Expected Cost

CEP  C P .R(T P )  C C .F (T P )

If:
• CEP: Proactive expected cost
• CP: Proactive cost
• CC: Corrective cost
• R(TP): Proactive interval reliability
• F(TP): Proactive interval failure probability
Conditional Reliability

 t  R (T  t )
R  
T  R (T )
Lewis Model
1
 n 1i  i

R   R i 1
 n  2 i 
i

If:
• Ri: Reliability of the i-th failure
• Ri-1: Reliability of the prior to the i-th failure
• n: Number of records
• i: I-th record
• δi: 1 if it is suspension and 0 if it is failure
Spare Parts and Vital
Supplies

Categorize spare Evaluate the

Define a period
parts, supplies amount used in
of analysis
and materials each category

Calculate the
Determine the
cumulative
frequency of use
frequency of
of each category
each category
 30.00% 120.00%

25.00% 100.00%

Cumulative frequency
20.00% 80.00%
Relative frequency

15.00% 60.00%

10.00% 40.00%

5.00% 20.00%

0.00% 0.00%
1 2 3 4 5 6 7
Categories
VITALS TRIVIALS
Order quantity
25

20
q

15
Quantity

10 q/2

T T T
0
0 10 20 30 40 50 60 70 80 90 100
Time

CPP  C c  C a  C f
CPP 
q C
P T oc

q P u
i
u
T 2
If:
• CPP: Orders cost for period
• Cc: Consumption cost for period
• Ca: Acquisition cost for period
• Cf: Financial cost for period
• q: Quantity of spare parts to order
• Pu: Unit price
• Coc: Cost of generating a purchase order
• T: Consumption time
• i: Interest rate
Moment to Generate an
Order
25

q 20

15
Quantity

10

qw Td
0
0 10 20 30 40 50 60 70
Time
 100.00%

90.00%

80.00%

70.00%
Service level (α)

60.00%

50.00%

40.00%

30.00%

20.00%

10.00%

0.00%
0 1 2 3 4 5 6 7 8 9 10
Optimal quantity (qw)

 q   
qw
e
 Td
T d  q

w
q 0 q!
If:
• α: Service level (> 95)
• q: Quantity of spare parts ordered
• qw: Quantity of spare parts to which the
next order should be generated
• λ: Spare consumption rate
• Td: Time delay in delivery of spare parts
Bibliography

• http://www.scielo.cl/scielo.php?script=sci_artt
ext&pid=S0718-33052013000100011
• Mora, A. (2009). Mantenimiento. México:
Alfaomega.
• Pascual, R. (2005). El Arte de Mantener.
Santiago: Beauchef.
• Tsang, A. & Jardine, A. (2013). Maintenance,
Replacement, and Reliability. Florida: Taylor
& Francis Group.