Maintenance Strategies

Why is this important?

Customer Business Objectives

Business objectives drive

the maintenance strategy, Maintenance Strategy
which in turn drives the
technologies and solutions
applied. Technology / Solution

Improved Business Performance

Maintenance strategy
definition and development
is a critical success factor in
the customer’s value chain.
Terminology

The four main maintenance strategies are:

• Reactive Maintenance (RM)
• Preventive Maintenance (PM)
• Predictive Maintenance (PdM)
• Proactive Centered Maintenance (PCM)
Terminology

Reactive maintenance (RM):

• Maintenance performed after a failure or after
an obvious, unforeseen threat of immediate
failure. In reactive maintenance, machines are
operated in a run-to-failure (RTF) mode, and
daily maintenance activities are driven by
unforeseen problems from assets breaking
down without detection of the impending
failure.
Terminology

Preventive Maintenance (PM):

• Maintenance tasks conducted at regular,
scheduled intervals based on average
statistical/anticipated lifetime to avoid failure—
including inspection, service and/or
replacement. Intervals may be calendar or
operating time.
Terminology

Predictive Maintenance (PdM):

• Maintenance based on the actual asset
condition (objective evidence of need)
obtained from in-situ, non-invasive tests and
operating and condition measurements. Also
referred to as Condition Based Maintenance
(CBM).
Terminology

Proactive-Centered Maintenance (PCM):

• A program of continuous maintenance
optimization based on feedback from Root
Cause Failure Analysis (RCFA) repairs,
quantitative PM’s, PdM routines, CM systems,
and operations.
Terminology

Condition Monitoring (CM):

• The process of recording measurements that
define condition without disrupting operation
(e.g., vibration, fluid and electrical
characteristics, and thermal gradients) and
comparing each to limits.
Terminology
Reliability Centered Maintenance (RCM):
• A systematic, disciplined process to ensure safety
and mission compliance that defines system
boundaries and identifies system functions, functional
failures, and likely failure modes for equipment and
structures in a specific operating context.
•RCM develops a logical identification of the causes
and effects (consequences) of system and functional
failures to arrive at an efficient and effective asset
management strategy to reduce the probability of
failure.
Terminology

Functional Failure:
• The System is no longer capable of
performing the intended function.
•For example, a pump that is designed to
produce 100 gpm at 200 psi is considered to
have functionally failed if it can only produce
90 gpm at 200 psi.
Terminology
Failure Modes & Effects Analysis (FMEA):
• A methodology for identifying the functions of an
asset, ways it can fail to perform those functions, the
causes of those failures, and the methods for
detecting or mitigating those failures.
•FMECA:Failure Modes, Effects, and Criticality
Analyses: An integral part of RCM directed to
determining type, probability, cause and
consequences of potential failures.
Terminology

Root Cause Failure Analysis (RCFA):

• A methodology used to identify the
fundamental cause(s) that, if corrected, will
prevent recurrence of an event or adverse
condition.
Terminology

Computerized Maintenance Management

System (CMMS):
• A computer system for measuring,
managing, and analyzing the maintenance
process. Includes MRO task planning and
scheduling, inventory control and
management, labor and material cost
accounting, and asset historical data.
 Terminology
The P-F Interval – Mechanical Asset Example (Centrifugal
Pump)

Vibration P-F interval 1-9 Process Performance Data (highly

The P-F interval is the months dependent on tuning of system /
interval between the instruments) ~1 week – 6 months
Wear Debris in oil P-F
occurrence of a interval 1-6 months
potential failure and IR Thermography P-F
Quantitative PM P-F
Interval 5-8 weeks
the decay into a interval 3-12 weeks

functional failure P P1 P2 Audible noise P-F

Time can be P3 interval 1-4 weeks

measured in seconds, P = Potential Failure P4 Heat by touch P-F

Is an identifiable condition which indicates P5
minutes, days, that a functional failure is either about to
interval 1-5 days
P6
months or years. occur or is in the process of occurring

P1-Px indicate
P7
noi ti dno C

Relays
detectability intervals
by various techniques
or technologies. F = Functional Failure
The point at which the asset fails to
deliver to it’s intended purpose F

Time
Comparative Total Maintenance spend for mature
maintenance programs

Maintenance Cost $/hp/yr

$20

From EPRI Power

Generation Study
$15

$10

$5

RM PM PdM PCM
Maintenance Strategies

No te : This c ha rt re p re s e nts e s ta blis he d

p ro g ra m s
Selecting the Right Maintenance
Strategy
The maintenance strategy is unique to each asset, and should
address the specific root-cause failure modes of the asset.
A mix of strategies can be applied to any one asset – for example,
PdM may be used for detectable fault types, but PM or RM may
apply for other failure modes.
The purpose of this section is to introduce the main steps in
selecting the right strategy:
1. Identify the Asset Base
2. Criticality Analysis
3. Develop the Strategy
4. Assign Technology & Tools
5. PM Task Optimization
1. Identify the Asset Base
The Master Equipment List (MEL)
A complete and accurate equipment library is
required for effective:
- PM/PdM work planning and execution
- Spare parts inventory management
- Cost accounting
- Reliability management
- Lifecycle cost management

It is important to note that many existing MELs

are in poor condition, with ambiguous naming
conventions and inaccurate hierarchy structure.
These may need significant re-work to be
applicable for Maintenance Management
2. Asset Criticality Ranking
Asset Criticality ranking helps determine the right level of asset management
resources (technology, parts, and people) for each asset. This enables the
business risk of each asset to be managed in an appropriate manner.
The criticality ranking process produces a balanced ranking of All Assets in the
plant – each with a 4-digit numerical criticality number.
A cross-functional team is usually assembled to agree on criteria weighting and
asset evaluation.
The Primary criticality ranking
criteria are:
• Safety,
• Environment & Regulatory
Compliance,
• Production,
• Maintenance & Operating Costs
• Product quality
Plus other criteria if relevant

Typical Asset Criticality

Ranking Tool
2. Asset Criticality Ranking
On the Asset Criticality Pareto Chart, natural “break points” appear to
segregate the assets into identifiable criticality classifications

For the most critical assets (ty p ic a lly 1 0 -1 5 % o f

a s s e ts ), a Reliability Centered Maintenance (RCM)
approach is used to determine the appropriate
maintenance strategy.
Critical assets are assessed using
Failure Modes & Effects Analysis
Criticality Ranking

(FMEA) process.
Less Critical assets are assigned a
strategy using standard Templates

Non-Critical
assets Run-to-
failure
5%
15% 30% (typical) 50% (typical)

Distribution of Assets
Course Review
• The four maintenance strategies are:
i. RM – Reactive Maintenance
ii. PM – Preventive Maintenance
iii. PdM – Predictive Maintenance
iv. PCM – Proactive Centered Maintenance
• A single asset or system may have several maintenance
strategies deployed to address its various failure modes.
• It is important for us to understand our Customer’s
maintenance strategy so we can build credibility and trust,
and advocate appropriate technology or services solutions
to help them meet their business objectives.