Maintenance Engineering

Lect. 3
Maintenance Policies

By

Prof. P.N. Muchiri

III. Decision support

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 Overview
• Maintenance concept decisions
• Definitions
• Maintenance actions
• CM, PM
• Maintenance policies
• FBM, UBM/TBM, CBM, OBM, DOM
• Maintenance concepts
• Q&D, LCC, TPM, RCM – customized concepts
• Wrap-up

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Maintenance concept decisions

• Level

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• ROI

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 Definitions
• Maintenance action
– Basic maintenance intervention, elementary task
carried out by a technician
• Maintenance policy
– Rule or set of rules describing the triggering
mechanism for the different maintenance actions
• Maintenance concept
– Set of maintenance policies and actions of various
types and the general decision structure in which
these are planned and supported

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Maintenance Maintenance Maintenance
actions policy concept
What do we do ? How are they triggered ? Which decision structure is used ?
reactive
Failure based Ad hoc
maintenance
Corrective preventive Q&D

action Time/used based

maintenance TPM
predictive LCC
Condition based
Precautionary maintenance RCM
action proactive
RCM
Design-out related
maintenance
passive
Customized
Opportunity based
maintenance

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Terminology !
 Business context

Functional analysis

Criticalility assessment
* system level (MIS)
* component level (MCC)

Maintenance strategy/policy decision

Rule based
Optimization OEM Experience based
analysis
(cost vs risk) recommendations Current practice
(RCM like)

Review

Workable overall maintenance plan

Design changes

Preventive maintenance plans

Condition monitoring

Inspection schedules
Breakdown protection
 Business context

Functional analysis

Criticalility assessment
* system level (MIS)
* component level (MCC) 10 % 40 %

50%
Maintenance strategy/policy decision

Rule based
Optimization OEM Experience based
analysis
(cost vs risk) recommendations Current practice
(RCM like)

Review

Workable overall maintenance plan

Design changes

Preventive maintenance plans

Condition monitoring

Inspection schedules
Breakdown protection
Intermezzo: Bicycle ...

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• Maintenance actions
– Corrective action
• e.g.
– Repair a punctured tire
– Replace tape on handlebars

– Precautionary action
• e.g.
– Check for bent, broken or missing spokes
– Check tire pressure

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• Maintenance policies
– Tires
• FBM: wait until tire puncture
• UBM: replace tires every 6-months
• CBM: check tires monthly and replace when necessary
• DOM: use air-free tires
• OBM: if you need to work on the brakes, check the tires

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• Components and maintenance
– Gears
• Derailleur gears vs hub gears
• Hubs are
+ More reliable (less exposed to dirt or weather)
+ Less vulnerable to damage in shipping
+ Require less maintenance attention
+ Can be shifted when bike is stationary (city traffic !)
+ Better protection of clothing (chain does not move
sidewards – utility bike)
– More limited range of gears
– Less efficient
– Heavier
– Cost (!)

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 – Brakes

Disc brake

Coaster brake
Spoon brake
(°1800s)

Drum brake Rim brake

(Cantilever)
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Rim brake 18
Disc brake (mountain bike) 19
Coaster brake 20
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Drum brake
Spoon brake 22
brake other technical other user
type braking performance
characteristics maintenance characteristics characteristics used for
brake pads
cables
mechanically
simple rim wear out
true rim needed lightweight rim heating heavier
rim nice weather cable operated easy to maintain tire size more expensive light-weight bikes

special hub needed

cable or rod hydraulic (special heavier
operated tools) more stress on more expensive downhill and off road
all weather hydraulic or mechanical (less wheel spokes less heavy to bikes,
disc better modulation mechanical modulation) (no pannier-racks) handle (touring bikes)
cable or rod more complex often rather weak
drum all weather operated less maintenance rather heavy utility and freight bikes
all weather less maintenance
coaster limited brake force pedal operated (complex !) freewheeling easy kids bikes
nice weather spoon (rubber, oldest (even before kids bikes
spoon road conditions rod or foot operated metal) excessive tire wear pneumatic tire) developing countries

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Brake type Performance Operational Technical Maintenance User issues Used in
issues issues issues

Rim Nice weather True rim needed Rim wear out Brake pads Heavier Light-weight
Cable operated Rim heating Cables More expensive bikes
Tire size Mechanically
simple
Lightweight
Easy to
maintain
Disc All weather Special hub More stress on Hydraulic Heavier Downhill and
Better modulation needed wheel spokes (special tools) More expensive off-road bikes,
Cable or rod (no pannier- Mechanical Less heavy to (touring bikes)
operated racks) (less handle
Hydraulic or modulation)
mechanical
Drum All weather Cable or rod Often rather More complex Rather heavy Utility and
operated weak Less freight bikes
maintenance

Coaster All weather Pedal operated Freewheeling Less Easy Kids bikes
Limited brake force maintenance
(complex !)

Spoon Nice weather Rod or foot Excessive tire Spoon (rubber , Oldest (even Kids bikes
Road conditions ! operated wear metal) before Developing
pneumatic tire) countries

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• Chains or ...

Chain

None

Shaft
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 Actions
– Corrective maintenance action (CM)
• Repair following a breakdown or loss of function
• e.g. pipeline rupture, motor stuck, ….

bread oven breakdown

– Precautionary action (PM)
• Any action mainly aimed at diminishing the failure
probability (and/or the failure effect)
• e.g. lubrication, bi-monthly spares (e.g. bearings)
replacement, inspection rounds, vibration monitoring,
design adjustments, ….

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motor alignment
 Policies
• Failure based maintenance (FBM)
• Reactive policy
• Maintenance is carried out only after a breakdown
occurred (CM)
• Aspects to consider
• Low cost if correctly applied
• Risk for secondary damage, safety hazards, …
• No planning possible: spares, manpower, …
• Unforeseen downtime
• Costs
• CFR behavior (constant failure rate)
• Examples
• Light bulbs, glass oven, …

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• Use/time based maintenance (U/TBM)
• Preventive policy
• Maintenance (PM) is carried at prespecified time
intervals (e.g. monthly, 1000 running hours); CM when
necessary
• Aspects to consider
• Traditional approach
• Many optimization models are available (basic trade-off:
CM vs PM costs)
• Planning possible: spares, manpower, …
• Downtime plannable
• Sometimes unnecessary actions carried out
• Predictable failiure behavior - IFR
• Examples
• car breaks, cutting device adjustments, bearing
replacement, rotating parts lubrication, cleaning, …

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• Condition based maintenance (CBM)
– “detection based maintenance”
• Predictive policy
• Maintenance (PM) is carried when considered necessary after
inspection; CM when necessary
• Low-level variant using checklists, instructions, human senses, …
CHECKLIST DEPALLETIZER
(daily check)

Operator: ........................
Date: ../../.. - Hour: ......
machine 1 machine 2
Heads:
Move sideways and check OK/not OK OK/not OK
- jamming of U section OK/not OK OK/not OK
- smooth movement of head (no jerkiness) OK/not OK OK/not OK
- correct play on runners OK/not OK OK/not OK

Run-out section:
Check roller table OK/not OK OK/not OK
Check buffer strips OK/not OK OK/not OK
Check chain before buffer OK/not OK OK/not OK

Turntable/delivery:
Rotate turntable and check
- chain OK/not OK OK/not OK
- rollers OK/not OK OK/not OK
- drive OK/not OK OK/not OK

Other remarks

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• Condition based maintenance (CBM)
– the “real” thing
• Predictive policy
• Maintenance (PM) is carried when a given system parameter
or system condition approaches or reaches a predetermined
value or situation; CM when necessary
• Aspects to consider
• From high risk environments to general industrial use
• Measurable condition/parameter
• Careful choice of method needed
• Requires usually (some) investment and expertise
• ICT requirements - e-maintenance
• Planning possible

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• Predictive techniques
– Vibration analysis
– Tribology (oil and wear particle analysis)
– Thermography (infrared)
– Ultrasound
– Electrical testing (resistance, HiPot)
– Process variables – NDT
• Examples
– Leakages, alignment problems, wear, …

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Vibration analysis

Before
lubrication

After
lubrication

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Tribology

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Thermography (Infrared)

Hot spot on cooling drum (food wrapping paper)

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Ultrasound

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• Condition based maintenance (CBM)
– the “hot topic” thing
• Prognostics (e-maintenance)

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• Opportunity based maintenance (OBM)
• Passive policy
• Maintenance (PM) is carried when “an opportunity”
arises; CM when necessary
• Aspects to consider
• Waiting for a maintenance job carried out at a
neighbouring part or installation
• Esp. for non-critical, long-living parts
• Examples
• Weapon systems, windmills, …

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• Design-out maintenance (DOM)
• Proactive policy
• Focuses on improving the design to make maintenance
easier (MTTR  0) or even eliminated it (MTBF  0)
• Aspects to consider
• Ergonomics
• Component reliability, modularity, standardization
• Ideally started when initially designing the machine
• If not, often combined with other design improvements
(e.g. safety, set-up time reduction, …)
• Examples
• Paint spraying robot: easier cleaning, less component
replacement; Wire cutting machine: less replacement
components cutting module, less maintenance due to
quality problems, lower breakdown risk

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 Wrap up
• Maintenance concept decisions
• Definitions
• Maintenance actions
• Maintenance policies
• CM, PM
• FBM, UBM/TBM, CBM, OBM, DOM
• Maintenance concepts
• Q&D, LCC, TPM, RCM –
customized concepts
• Wrap-up

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What do you think of ....

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Interesting insights or boring old wisdom ?

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