Source: STANDARD HANDBOOK OF PLANT ENGINEERING

SECTION 2

EFFECTIVE MAINTENANCE
MANAGEMENT

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 EFFECTIVE MAINTENANCE MANAGEMENT

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 Source: STANDARD HANDBOOK OF PLANT ENGINEERING

CHAPTER 2.1
PRINCIPLES AND PHILOSOPHY
William N. Berryman
Engineering Consultant
Morgan Hill, California

Condition-based maintenance (CBM) programs are established based on information col-

lected, such as equipment failure and adjustment points, and determination of mean time
between failure (MTBF) of equipment. This information can be gathered in many ways,
through data collection processes in the program architecture, predictive technologies (e.g.,
vibration analysis, ferrography, and thermography), and building automated systems that pro-
vide input based on the various adjustments that take place.
This information is compiled and, through either software or statistical analysis, the condi-
tion of the equipment can be established at a point in time, or a prediction of when equipment
maintenance should be performed (in terms of frequency or run time) can be made.
This is one of the most cost-effective methodologies of maintaining equipment, because
only required maintenance is performed. Establishing criticality of the equipment plays a
large part in these cost savings.
Reliability-centered maintenance (RCM) is a common application of time-based sched-
uled preventive maintenance procedures, and of predictive maintenance technologies applied
to a specific application that allows for equipment life optimization.
RCM is a very effective methodology for many maintenance programs and, if the program
architecture is designed appropriately, could provide cost savings and cost avoidance oppor-
tunities.
The keys to an effective RCM are the following:
1. Identifying a delivery method—that is, computerized maintenance management system
(CMMS) procedures
2. Ensuring that all equipment is identified
3. Establishing criticality of all equipment
4. Deciding what equipment to target for predictive maintenance
5. Deciding what equipment to target for preventive maintenance
6. Deciding what equipment should be run to failure
7. Deciding how data should be collected in the field
8. Selecting data and determining how the data should be used
With these tools, an effective RCM program can be established. Sustaining any mainte-
nance program can be a challenge, but can be accomplished by utilizing processes and proce-
dures that establish the core of the program.
Time-based and task-based maintenance has been an effective methodology for many
businesses, especially businesses whose budgets do not allow for implementation of costly
software and hardware. Although not as effective as RCM and CBM programs, these pro-
grams do have their place in today’s environment, but there are risks.
Time-based programs, without the use of predictive tools, will only extend the life of
equipment, but all rotating equipment will fail in time. However, time-based programs could
be improved by allowing for data collection. There is additional cost involved based on the
time spent on the equipment, but some other costs are deferred (CMMS software, etc.). Using

2.3

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 PRINCIPLES AND PHILOSOPHY

2.4 EFFECTIVE MAINTENANCE MANAGEMENT

a simple spreadsheet, this program could be effective for small preventive maintenance (PM)
programs.
Run-to-failure methodology is generally the most costly method of maintenance for the
following reasons:

1. When rotating equipment does fail, it is usually catastrophic, causing more damage and
raising the cost of repairs.
2. If the failure event is on a critical piece of equipment, bringing the equipment or system
back on line will usually take more time and be more costly.
3. To reduce the downtime in a run-to-failure program, additional spare parts must be avail-
able.
4. All failures using this methodology are unplanned events and in many cases have other
consequences that usually equate to some additional cost or customer impact.
Many environments still utilize this methodology, but not all in these categories: office
environments, restaurants, and warehouses. In many cases, there is no business impact if
equipment fails. It is just an inconvenience
due to its catastrophic nature.

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