Modern Maintenance Management

Approaches

Dr. Attia Hussien Gomaa

attiagomaa@yahoo.com

Refer to BS3811:2000,

Maintenance is the work under taken in order to

keep or restore a facility to an acceptable standard
level.

Maintenance management is a powerful

systematic methodology to maximize the facility
performance and to improve the maintenance
resource productivity, through optimizing the
maintenance policies for the critical equipment,
[Gomaa (2005) and Dunks (2005)]

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 Maintenance Policies
(5)
(1) Total-Based
Failure-Based Global (GM):
Reactive (ReM): - OSM
- RTF - TPM
- CM
- FF (3)
Condition-Based
(2) Predictive (PdM):
Time-Based - Oil analysis
Preventive (PM): - Vibration analysis (4)
- Calendar: - Temperature analysis Risk-Based
Weekly - Pressure analysis Proactive (PoM):
Monthly; .. etc. - Wear analysis - RCFA
- Running: - Efficiency analysis, - HAZOP
1000 R.H. - .. etc. - FMEA \ FMECA
1000 K.M.; .. etc. - RCM \ RCM2
- RBI

Figure (1): Maintenance policies,

[Venkatesh, 2003, Gomaa 2005, Gomaa et al. 2005].

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 10) TPM
9) OSM
8) RBI
7) RCM\ RCM2
6) FMEA\FMECA
5) HAZOP
4) RCFA
3) PdM
2) PM
1) RTF
Before 1950 1950 - 1970 1970 - 1990 After 1990
1st generation 2nd generation 3rd generation 4th generation
Reactive Preventive Proactive Global
approach approach approach approach

Traditional Modern
maintenance management maintenance management
Maximize equipment Maximize system
availability availability & productivity

Figure (2): Maintenance management history.

[Venkatesh, 2003, Gomaa 2005, Gomaa et al. 2005].

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Proactive maintenance (PoM) is a systematic
approach to establish a good maintenance program for
critical equipment to improve the system availability
and reduce the maintenance cost, by focusing on the
most important functions of the system, and avoiding or
removing maintenance actions that are not strictly
necessary [Deshpande, 2003 and Garcia et al., 2003].

Root cause failure analysis (RCFA) is a

systematic methodology to identify true causes of
failures. It can identify and correct design, operations,
maintenance, training, etc.

Failure mode effect criticality analysis

(FMEA) provides a logical method to identify failure
modes; criticality of these failures; proposed
procedures to address the consequences of these
failures; and recommendations regarding the design of
the system. It is a proven technique used to detect
possible failure modes.

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 Reliability Centered Maintenance (RCM\

RCM2)
RCM is a systematic risk based maintenance
approach to determine the best maintenance
requirements for the critical equipment. RCM is used
to control maintenance operations and costs while
improving reliability.

RCM is the optimum mix of reactive, time- or interval-

based, condition-based, and proactive maintenance
practices.

RCM analysis is carried out in sequenced steps:

(1) System selection and information analysis;
(2) System boundary definition;
(3) System description and functional block diagram;
(4) System function and functional failures;
(5) Failure mode and effects analysis;
(6) Logic (decision) tree analysis; and
(7) Task selection

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 Risk based inspection (RBI)

RBI is a process of carrying out risk analysis to

determine an optimum inspection plan for the critical
systems, [API 581:1998].

System Existing HAZOP Risk

selection inspection plan analysis

Corrective Implementatio Future Proactive

actions n inspection plan policy

Figure (3): RBI for critical systems.

RBI is carried out in sequenced steps:

(1) System selection and information analysis;
(2) HAZOP for each major component;
(3) Risk Analysis;
(4) Resolution of actions (proactive policy);
(5) Develop inspection plans (short, annual, and long
terms);
(6) Execution of inspection; and
(7) Repairs & modifications.

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Hazard operation study (HAZOP) is a structured
method for identifying hazards and problems
associated with the operation of a plant.

The results of a HAZOP study allow engineers to

improve the safety of an operation and to highlight
operability problems starting at an early stage in project
development to existing plants which have been
operating for many years. 

For each major component of the item being studied

use HAZOP approach to identify the following:
 Internal pressure envelope deterioration
 External pressure envelope deterioration
 Internals deterioration e.g. tubes
 Location of deterioration
 Rate of deterioration
 Probable failure mode

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 Global Maintenance (GM)

GM is an integrated approach for maintenance management

to maximize system/equipment effectiveness to achieve
optimum life cycle cost of production equipment; [Venkatesh,
2003]. Figure (4) shows a global approach outline. There are
two global approaches which are optimal system maintenance
(OSM) and total productive maintenance (TPM).

Critical
Scope Time resources
For the
different
Global management
Performance approach Cost levels

Quality
.. etc.
HSE

Maintenance
Production
management
management Quality
.. etc. management

Global approach
Resource/cost
management
Communication
management
Risk Procurement
management management

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 Figure (4): Global approach outline.

Optimal System Maintenance (OSM)

OSM approaches focus on mathematical modeling and

developing optimal policies to inspect, repair, or replace
equipment based on its specific reliability characteristics.

Generally, an OSM policy may be the one which either:

(a) minimizes system maintenance cost rate;

(b) maximizes the system reliability measures;

(c) minimizes system maintenance cost rate while the

system reliability requirements are satisfied; or

(d) maximizes the system reliability measures when the

requirements for the system maintenance cost are
satisfied

[Wang, 2002, Komonen, 2002, Kyriakidis and Dimitrakos,

2004, Shalaby et al., 2004, and Gomaa et al. 2005]

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 Total Productive Maintenance (TPM)

TPM is an integrated approach for maintenance

management to maximize plant effectiveness by
establishing a comprehensive productive-maintenance
system.

TPM is the systematic execution of maintenance by all

employees through small group activities.

The dual goals of TPM are zero breakdowns and zero

defects.

TPM was defined by Japanese Institute of Plant

Engineers (JIPE) in 1971.

TPM involves operational and maintenance staff

working together as a team to reduce wastage,
minimize downtime and improve end-product quality.

[Tsang, 2000, Eti et al., 2004 and Gomaa 2005].

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 TQM

Documentation tools Implementation tools

Productive systems Procurement

ISO series management management

TPM JIT / SC

Maintenance Safety Process Human resource

management management management management
RCM RBI PCP TA

Figure (5): Relation between the different modern management approaches.

A company

TQM Level 1
Productive Sectors Supportive Sectors

ISO Plant P01 Plant P0K Plant P0N

TPM Level 2
JIT
Production management Resources management

RCM Level 3
Process Equipment Materials HR
RBI Manag. Manag. Manag. Manag.

FMEA
Level 4 Production area/site P0K
HAZOP (Equipment , Manpower, Materials, Safety, .. etc.)
PM-PdM

Figure (6): TPM management level.

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