Maintenance Management - DR Attia Gomaa - 01!12!201 - 230606 - 232549

‫وما توفيقي إال باهلل‬
Maintenance Management
Zero
Failures
RAMS
High Level Maintenance
Maintenance Strategy Planner / Leader / Manager
Dr. Attia Gomaa

Industrial Engineering Professor & Consultant
Mechanical Eng. Department – Shoubra Faculty of Eng. - Benha University
& Engineering and Science Services - American University in Cairo
Facebook: Attia Gomaa & Group: Maintenance Management – Dr. Attia
RCM December 2018

Maintenance Management
Contents:
1. Maintenance Types & Policies

2. Maintenance Management
3. Maintenance Information
4. Maintenance Planning
5. Maintenance Control
6. Maintenance KPIs
7. Reliability Analysis
8. Failure Analysis
9. Case Studies
Deming, PDCA, 1950
RCM Maintenance Management Best Practice – Dr. Attia Gomaa - 2018 2

Rules of the Course
This is an Open Discussion Course:
– Share Knowledge ‫– تبادل المعرفة‬

– Share Experiences ‫– تبادل الخبرات‬ Team Approach
– Share Best Practices ‫– تبادل التجارب الجيدة‬
– Share Questions ‫– تبادل األسئلة‬
Remember … You can’t do it alone!
Let us be a teamwork.
Maintenance
All activities involved in keeping a system in working order
 Preventive Maintenance (Planned Maintenance)

A plan that involves routine inspections, servicing, and
keeping facilities in good repair to prevent failure
 Breakdown Maintenance (Unplanned Maintenance)

Remedial maintenance that occurs when equipment fails
and must be repaired on an emergency or priority basis
Failure

TYPES OF MAINTENANCE
British Standard (3811:1993) classified maintenance types as
the followings:
MAINTENANCE
Planned (What? When? How?) Unplanned

Maintenance Maintenance
Unplanned
Preventive Corrective
Maintenance (emergency
Maintenance)
Breakdown
Time-based Condition-based
Maintenance Maintenance Planned
Corrective
(Planned CM)

Refer to (ISO 14224:2016):
PM CM

Maintenance:
Objectives:
RAMS Quality
Continuous Improvement
Cost
Reliability
Safety
RAMS
Availability
Maintainability Resource Utilization

(Cost Reduction)
Maintenance Policy?
Maintenance / Failure Cost Analysis
Direct costs Downtime losses

Overhead costs
• Material • Process Losses
• Technical o/h
• Manpower • Quality Losses
• Office o/h
• Tools • Safety Losses

Tradeoff Between Repairs and PM
Minimum
Level of
Preventive
Maintenance
Maintenance Policy?
Degree of Preventive Maintenance

Pump Life Cycle Cost Analysis; for example:
Maintenance Cost = (20% to 30%) from Life Cycle Cost

Common Maintenance Strategy (CMS)
Global Maintenance Management (GMM)
Strategy is a systematic method

to achieve a certain objective
Strategy is a high level plan to

achieve one or more goals
Your success as a manager depends on making a common

strategy to be aware with everything on the organization like a
standard strategy for each department.
Vidoe

Five steps in the Common Maintenance Strategy (CMS):
1- Optimum Maintenance Strategy
2- Planning and Scheduling
3- Optimize Resource Levels (Critical Resources)
4- Key Performance Indicators (KPIs)
5- Benchmarking (Internal / External)
Six important elements to the CMS:
1- Leadership & Organization Structure
2- Facility Availability
3- Work Management
4- Materials Management
5- Change Management (Proactive)
6- Continuous Improvement
Terms To Understand
• Quality & Reliability • Proactive & Reactive
• Availability & Maintainability • Inventory Analysis
• Maintenance Insurance • KPIs (Key Performance Indicators)
• Cost Effective • Benchmarking (Internal / External)
• Maintenance Cost (25% Operational cost) • Operation efficiency 99.25%
• Optimize (= < >) (SCE, Process ..) • Critical Equipment Reliability 99.89 %
• Planning & Schedule • Planned v Unplanned 95%
• Planning (What , When , How) • Facility Availability over 6 years 98.8%
• Critical Failure • Spare Parts
• Risk (Safety, Financial) • Insurance / consumable
• Facility Availability • Safety Stock (min. stock level)
• Equipment Reliability • Insurance Stock (SCE)
• Mechanical Integrity • OEE (Overall Equipment Effectiveness)
• Sharing Information & Experience • …. etc.

Root Causes of Pump Failures
• Lack of maintenance (clean, check, Replace, ... etc.) > 30%
70% Maintenance
Management
• Operating Conditions (flow rate, head, speed, … etc.) > 20%
• Human errors (not qualified, under stress, … etc.) > 10%
• Unsafe conditions (Near-miss) > 5%
• No Information (references, manuals, history, … etc.) > 5%
• Poor quality of spare parts (low cost, … etc.) >20%

• Poor design (selection, location, … etc.) >10%
• Others <10%

Preventive Maintenance Tasks: S, L, OC, HT, FF
• S (Servicing Task) - Replenishment of consumable materials
depleted during normal operations
• L (Lubrication Task) - Replacement of a lubricant based on

manufacturer’s predicted or measured life of the lubricant
• OC (On Condition Task) - Periodic or continuous inspection

designed to detect a potential failure condition prior to
functional failure
• HT (Hard Time Task) - Scheduled removal of an item or a

restorative action at some specified age limit to prevent its
functional failure
• FF (Failure Finding Task) - A preventive maintenance task

performed at a specified interval to determine whether a
hidden functional failure has occurred.

Servicing:
The replenishment of consumable materials that are depleted during

normal operations
Lubrication:
The scheduled lubrication of a component (usually based on the

manufacture’s recommendations) where the item’s design requires a
non-permanent lubricant for proper operation
On-Condition
Periodic or continuous inspection designed to detect a potential failure

condition prior to functional failure
Hard Time Task:
Scheduled removal of an item or a restorative action

at some specified age limit to prevent its functional
failure
Failure Finding (special tools):
A preventive maintenance task performed at a

specified interval to determine whether a hidden
functional failure has occurred
Predictive Maintenance: Off line
On line
Visual Vibration
Inspection analysis Oil
analysis
... etc.
Efficiency Condition based Temperature

analysis Maintenance analysis
Wear Pressure
analysis analysis
Motor
Ultrasonic
Current

Which Technology offers the best return?
Infrared Thermography
15%
Ultrasonic 10%
45%
5% Vibration
Motor Current Analysis
10%
15% %
Steam Trap
Oil
Of all the various maintenance technologies, Vibration Analysis provides the greatest
percentage of payback when adopting a predictive maintenance program
P-F: Potential Failure Mode

Failure Analysis Concept: (Failure & Failure Mode)
Failure Mode: High Temperature > 80 o C
100
90
70 80
P-F: Potential P-F: Potential
Failure Mode Failure
Good Early Hidden Risk

Conditions Failure Failure Failure
Normal Failure Failure Engine

Mode Mode Failure
PM W/O Call for Call for B/d

Service Repair Emergency
Planned Planned Planned Unplanned

Maintenance CM CM CM
Evaluation: A B C D
Maintenance Policy?

System / Equipment Criticality
Low Medium High Very High
Low Medium High Safety Critical
Production Production Production Elements
losses losses losses (SCE)
Refer to ISO 14224 / API 580 / API 581 / ….
Low Medium High / Very High

Road Map for Maintenance Policies (Common Maintenance Strategy)
What? When? How?
Unplanned (5)
Maintenance Planned
Total-Based
Maintenance (TQM Applications)
- TPM - OEE
(1) - CMS
Current Maintenance Program
Failure-Based - Asset Management

(3)
Reactive (ReM): - EAM, … etc.
Improvement / Optimize
Condition-Based
- RTF (2) Predictive (PdM): (4) Risk-Based
Critical Systems
- CM Time-Based - Oil analysis Proactive (PaM):
- BD Preventive (PM): - Vibration analysis 1- Criticality Analysis (SCE, PCE)
:: - Calendar: - Temperature analysis 2- Failure Analysis:
Weekly - Trouble Shooting
- Pressure analysis
Monthly - RCFA (Why-Why?) for CM W/o
- Wear analysis - FMEA for Failure Modes
Uniform :: - Color analysis - Failure Finding (FF) for SCE
± 10% - Running: - Efficiency analysis 3- Update Maintenance Program
1000 Hours ::
10000 Km Most Effective International Standards:
:: • RBM / RCM
Parameters • RBI / RBT
Long Term Continues Improvements  Teamwork Project (Maintenance, Operation, Safety)

Term Description
RTF Run To Failure
CM Corrective Maintenance
BD Breakdown Maintenance
PM Preventive Maintenance
PdM Predictive Maintenance
PaM Proactive Maintenance
RCFA Root Cause Failure Analysis
FMEA Failure Mode Effect Analysis
FF Failure Finding Task to discover the hidden failures
RBM Risk Based Maintenance
RCM Reliability Centered Maintenance
RBI Risk Based Inspection
RBT Risk Based Testing or Instrumented Protective Function (IPF)
GMM Global Maintenance Management
OSM Optimal System Maintenance
TPM Total Productive Maintenance
CMS Common Maintenance Strategy
EAM Enterprise Asset Management
TQM Total Quality Management

Asset Management:

Proactive Maintenance (PAM):

Comparison of different maintenance policies
Policy Approach Goals
Minimize maintenance
Run to failure (fix-it when
Reactive costs for non-critical
broke).
equipment.
Time or Use-based Minimize equipment
Preventive
maintenance program. breakdown.
Discover hidden failures

Maintenance decision based on
Predictive and improve reliability for
equipment condition.
critical equipment.
Minimize the risk of

Proactive Detection of sources of failures.
failures for critical systems.
Maximize the system
Global Integrated approach.
productivity.

Risk-Based
A comparison among proactive maintenance approaches
Identification of root causes of
RCFA Eliminate failures.
failures.
Improve equipment
FMECA Identification of criticality of failures.
availability.
Identification of hazards and

HAZOP Improve HSE effect.
problems associated with operations.
RBM / Determination of best maintenance Keep system function &

RCM requirements for critical systems. improve reliability.
Determination of an optimum Improve system HSE

RBI
inspection plan for critical systems. and availability.

Total-Based  TQM
Comparison among global maintenance approaches
GMM Total View Maximize Facility Reliability
Optimization approach for Maximize reliability measures

OSM the global maintenance and minimize maintenance cost
system. rates.
Comprehensive productive- Maximize plant effectiveness

TPM
maintenance system. and resource productivity.

Maintenance Leader rests on three legs

Maintenance Management:
5) Improvement 2) Planning
(Planned
+/- 1) Define Performance)
(Information) W/O
(Identify)
4) Control
(Actual / Planned)
3) Execution
(Actual
KPIs Feedback Performance)

Maintenance Management System:
(Failure Analysis, RAMS, Job, Resources productivity, Cost efficiency, Doc. , … etc.)
(System, Process, Equipment, Job, Resources, Cost, References… etc.)
Targets Cost Plan Cost Control

Define (Maintenance Information / Identify)
• Direct Costs Cost Efficiency

• Overhead Costs
• Downtime Losses Analysis
KPIs
Financial
Feedback
Process Satisfaction
Feedback
Job Plan Execution Job Control
• Corrective Maintenance
W/o
• Reduce Failures RAMS Analysis
• Preventive Maintenance
• Reduce Downtime • Improve Reliability
• Predictive Maintenance
• Reduce Hazards • Improve Availability
• Design Changes
• Improve Maintainability
• Improve Safety
Feedback KPIs
Resources
Resource Plan Resource Control
• Materials Resource
• Manpower
• Service Equipment Productivity
• Special Tools Critical
Analysis KPIs
• Method Resources

1) Define
(Maintenance Information)
1. Criticality Analysis
2. System Structure
3. Equipment Data Sheet
4. PM Program (Job, Time, Resources, Cost)
5. Maintenance Manuals
6. References , … etc.

2) Planning
1. Estimation (Targets)
2. Work Orders
3. Job Plan
4. Resources Plan
5. Cost Plan
6. Shutdown Planning
7. Standard Templates, … etc.

3) Execution Feedback
W/o Feedback
OK / Done / Complete
Quantitative Qualitative
“Measurable” “Comments”
 Indicators??
Close-out

4) Control
• KPIs Analysis
• Reliability Analysis
• Availability Analysis
• Maintainability Analysis
• Safety Analysis
• Critical Resources Productivity
• Cost Efficiency

5) Improvement
1. Failure Analysis
2. Trouble Shooting
3. Root Cause Failure Analysis (RCFA)
4. Reliability Analysis (Prediction)
5. Failure Mode Effect Analysis (FMEA)
6. Fault Diagnostics
7. Update PM Program
8. Update Work Order

5) Improvement (Recommendations):
 Effectiveness (RAMS) Improvement:
• Reliability Improvement:
•
• CMP
• Availability Improvement: Change
• Management
• Plan
• Maintainability Improvement:
•
•
• Safety Improvement:
• Motivation
•
 Efficiency (Resource & Cost) Analysis: Training

• Resource Improvement:
•
Standardization
• Cost Improvement:
•

Maintenance Management - Case Study Methodology:
Facility / Site
Top
(Facility)
Level I
System System System
/ Area / Area / Area
Middle
(Systems)
Level II
Power System Steam System
Turbine Boilers
…... …... Operational

(Critical Equipment)
Equipment Equipment Level III

Facility / System Structure: Facility Management:
3) Site Level:
1. Master Plan (Milestones)
Facility 2. Maintenance Budget Plan
3. Benchmarking (Targets)
System #1 4. KPIs (OEE & Losses)
Equipment System Management:

2) System Level:
Item #1 1. Master Plan
2. Material Plan
Item #2 3. Cost Plan
4. KPIs (RAMS & Cost)
….
Equipment Management
Equipment
1) Equipment Level:
Item #1 1. Criticality Analysis
Item #2 3. Maintenance Program Levels
4. Maintenance Plan
System #2 …. 5. Work Order & Feedback
6. Failure Analysis (RCFA & FMEA)
7. Maintenance Control (KPIs)

Computerized Maintenance Management System (CMMS)

Case Studies
(Maintenance Management Methodology)

Maintenance Management System:
(Failure Analysis, RAMS, Job, Resources productivity, Cost efficiency, Doc. , … etc.)
(System, Process, Equipment, Job, Resources, Cost, References… etc.)
Targets Cost Plan Cost Control

Define (Maintenance Information / Identify)
• Direct Costs Cost Efficiency

• Overhead Costs
• Downtime Losses Analysis
KPIs
Financial
Feedback
Process Satisfaction
Feedback
Job Plan Execution Job Control
• Corrective Maintenance
W/o
• Reduce Failures RAMS Analysis
• Preventive Maintenance
• Reduce Downtime • Improve Reliability
• Predictive Maintenance
• Reduce Hazards • Improve Availability
• Design Changes
• Improve Maintainability
• Improve Safety
Feedback KPIs
Resources
Resource Plan Resource Control
• Materials Resource
• Manpower
• Service Equipment Productivity
• Special Tools Critical
Analysis KPIs
• Method Resources

Maintenance Management - Case Study Methodology:
Facility / Site
Top
(Facility)
Level I
Middle
(Systems)
Level II
Turbine Boilers


Facility / System Structure: Facility Management:
3) Site Level:
1. Master Plan (Milestones)
Facility 2. Maintenance Budget Plan
3. Benchmarking (Targets)
System #1 4. KPIs (OEE & Losses)
Equipment System Management:

2) System Level:
Item #1 1. Master Plan
2. Material Plan
Item #2 3. Cost Plan
4. KPIs (RAMS & Cost)
….
Equipment Management
Equipment
1) Equipment Level:
Item #1 1. Criticality Analysis
Item #2 3. Maintenance Program Levels
4. Maintenance Plan
System #2 …. 5. Work Order & Feedback
6. Failure Analysis (RCFA & FMEA)
7. Maintenance Control (KPIs)

System Selection: (2014)
• System: Steam Boilers (3 units) Criticality: High
• Equipment: Feed Water Pumps (4 units 3 Running & 1 Standby)

Focus Group
Focus Group 1. RCM Specialist "Consultant: Dr. Attia"

2. Facilitator “Site manager“
3. Planning Engineer “Maintenance Planner”
Process Maintenance 4. Mechanical Maintenance Engineer
RCM 5. Electrical Maintenance Engineer
6. Instrumentation Maintenance Engineer
7. Inspection Engineer
Safety
8. Safety Engineer
9. Process Engineer

1) Define (Identify)
(Maintenance Information)
1. Criticality Analysis
2. System Structure
4. PM Program (Job, Time, Resources, Cost)
5. Maintenance Manuals
6. References , … etc.
Good Data = Good Outputs

Bad Data = Bad Outputs

System Structure:
Facility
Steam System
Boiler
....
....
Pump Station
Pump unit
Coupling
Motor
Valves
System #2 .....

Equipment Record (Data Sheet)
Reference Data:
• Area / Location: 410
• System: Steam Boilers
• TAG No.: 410-P-001
• Criticality: High
• Equipment Type: Pump
• Number of Units: 4 units
• Working Conditions: 24 hours/day
(3 Running & 1 Standby) (A/B/C/D)
• Maintenance Resp.: Outsource (XX)
Details: (Main 10 parameters required to identify the equipment)

• Pump Type: - Geometric:
• Fluid: - Number of Stages:
• Flow Rate: - Suction Pressure:
• Discharge Pressure: - Design Speed:
• Power: - Available NPSH:

PM Program / Unit (Maintenance Manual & Experience):
Quarter Semi-Annual Annual
PM Level Weekly Monthly (2000 RH) (4000 RH) (8000 RH)
Job
Check
5 Steps:
Replace
1) Define
Maintenance Type 2) Planning
Downtime 3) Execution
Time
hours / order
Maintenance Time
4) Control
hours/order 5) Improvement
Manpower
Cost Resources
Man . hour
Special Tools
Service Eq.
Cost LE/order/unit

Equipment Record (Data Sheet)
Reference Data:
• Area / Location: 410
• System: Steam Boilers
• TAG No.: 410-P-001
• Criticality: High
• Equipment Type: Pump
• Number of Units: 4 units
• Working Conditions: 24 hours/day
(3 Running & 1 Standby) (A/B/C/D)
• Maintenance Resp.: Outsource (XX)
Details: (Main 10 parameters required to identify the equipment)

• Pump Type: Centrifugal - Geometric: Horizontal
• Fluid: Water - Number of Stages: Single Stage
• Flow Rate: 44 m3/hr - Suction Pressure: ATM
• Discharge Pressure: 8.9 Kg/cm2 - Design Speed: 3000 RPM
• Power: 22 Kilowatt - Available NPSH: 5.66 m

PM Program / Unit (Maintenance Manual & Experience):
Cleaning Cleaning Cleaning Cleaning Cleaning
Check operation Check operation Check operation Check operation Check operation
Check seals Check seals Check seals Check noise Check noise
Check noise Check noise Check noise Check valves Check valves
Check valves Check valves Check bearing Check coupling
Check
Job
Check bearing Check coupling Check impeller

Check impeller Check casing
Check casing Check shaft
Check strainers Check strainers
Check motor Check motor
- - - Replace seal Replace seal
Replace
Replace bearing
Maint. Type Running Running Running Shutdown Shutdown
Downtime
- - - 8 12
Time
hours / order
Maint. Time
hours/order 1 2 3 10 15
Manpower 2 Mech. 2 Mech. 2 Mech. 2 Mech. + 1 Elec. 3 Mech. + 1 Elec.
Cost Resources
Man . hour 2 4 6 30 60
Special Tools
Service Eq.
Cost
LE/order/unit 200 500 1,000 4,000 10,000

Feed Water Pump:
Coupling
Motor Pump
Schematic diagram
of centrifugal pump:
1. Inlet valve;
2. Vacuum gauge;
3. Centrifugal pump;
4. Torque meter;
5. Motor;
6. Pressure gauge;
7. Flow meter; and
8. Outlet valve.
…

Centrifugal Pump Parts (Maintenance Manual)

Maintenance Program Matrix – Item Level
System: Steam System Equipment: Feed Water Pumps Criticality: High
PM Levels
Policy # Maintainable Items
W M Q 6M A Disciplines
1 Mechanical Seals (1) C C C R R M
PM
2 Bearing (2) C C R M
3 Shaft Sleeve C M
4 Shaft C M
5 Coupling C C M
6 Impeller C C M
7 Casing C C M
RTF
8 Strainers C C M
9 Valves C C C C I
10 Electric Motor C C E
11 Oil C C C R M
12
C: Check R: Replace M: Mechanical E: Electrical I: Instrumentations

2) Planning
1. Estimation (Targets)
2. Work Orders
3. Job Plan
4. Resources Plan
5. Cost Plan
6. Shutdown Planning
7. Standard Templates, … etc.

PM Information Importance: Annual
Estimation
Annual Frequency / Unit
0 1 2 3 4 5 6 7 8 9 10 11 12
M M M M M M Q M M
S Q
Annual Analysis (Targets); for examples A
Level Indicator Base Unit Target
Annual Cost PM LE/year 112,000
Cost
Top
.... .... .... ....

Equip. Down time PM Hours / Equip. 20
Middle
Maintenance time PM hours 348

Time
Equip. Availability PM % 99.8 %

.... .... .... ....
Workers PM+20%CM Man-hours 1027
Operational
Resources
Bearing 10
Spare Parts PM+20%CM
Mechanical Seal 10
4 workers
Labor Productivity % 13 %
2000 hours/y
.... .... .... ....

Information For Maintenance Planning:
The maintenance information for a
water pumping station is as follows:
System: A Water Pumping Station
(4 units 3 Running & 1 Standby)
Working Conditions: 24 hours/day
Maintenance: Outsource (Subcontractor)
Job Information:
PM Level Quarter Semi-Annual Annual
Weekly Monthly (2000 RH) (4000 RH) (8000 RH)
Cleaning Check …
Cleaning Cleaning Cleaning
Maintenance Task Check … Change seal
Check … Check … Check …
Change seal Change bearing
Maintenance Type Running Running Running Shutdown Shutdown
Cost Rate
200 500 1,000 4,000 10,000
LE/order/unit
Based on this information; discuss the

Annual Maintenance Schedule , Cost Plan & Resource Plan (Material, … etc.).

Annual Maintenance Schedule
0 1 2 3 4 5 6 7 8 9 10 11 12
M M M M M M Q M M
Q S
A
Plant: Water Station Equipment Type: Pumps Period: 2018
Last Major Months - 2018

# Equipment ID Maintenance 1 2 3 4 5 6 7 8 9 10 11 12
1 Pump #1 P1 12/2017 A
2 Pump #2 P2 10/2017 A
3 Pump #3 P3 8/2017 A
4 Pump #4 P4 5/2017 A
Milestones
M: Monthly Q: Quarter S:Semi-Annually A: Annual
Meeting  Must be Accepted (Operation & Maintenance)

Annual Maintenance Schedule (Maintenance Matrix)
(52 Weeks or 12 Months)
0 1 2 3 4 5 6 7 8 9 10 11 12
M M M M M M Q M M
Q S
A
Months - 2018
# Equipment ID Ref.
1 2 3 4 5 6 7 8 9 10 11 12
1 Pump #1 P1 M M Q M M S M M Q M M A
2 Pump #2 P2 M M S M M Q M M A M M Q
3 Pump #3 P3 M M Q M M A M M Q M M S
4 Pump #4 P4 M M A M M Q M M S M M Q

Master Maintenance Schedule (3 Areas / 12 Pump Units)
Months - 2018
Area
Equipment ID Ref.
1 2 3 4 5 6 7 8 9 10 11 12
Pump #1 P1 M M Q M M S M M Q M M A
Pump #2 P2 M M S M M Q M M A M M Q
#1
Pump #3 P3 M M Q M M A M M Q M M S
Pump #4 P4 M M A M M Q M M S M M Q
Pump #5 P5 M Q M M S M M Q M M A M
Pump #6 P6 M S M M Q M M A M M Q M
#2
Pump #7 P7 M Q M M A M M Q M M S M
Pump #8 P8 M A M M Q M M S M M Q M
Pump #9 P9 Q M M S M M Q M M A M M
Pump #10 P10 S M M Q M M A M M Q M M
#3
Pump #11 P11 Q M M A M M Q M M S M M
Pump #12 P12 A M M Q M M S M M Q M M
Annual Cost Plan
PM Level W M Q S A
Annual Frequency / Unit 40 8 2 1 1
4 Units 160 32 8 4 4
Cost / Order 200 500 1000 4000 10000
Annual Maintenance Cost = 112,000 LE
Months - 2018
# Equipment ID
1 2 3 4 5 6 7 8 9 10 11 12
Number of Weekly PM
4.5 4.5 19 4.5 4.5 19 4.5 4.5 19 4.5 4.5 19
Maintenance Cost 28 28 28 28
(1000 LE)
112
Annual Cost Plan (2018)
System: Water Pump Systems
Months - 2018
# Equipment ID
1 2 3 4 5 6 7 8 9 10 11 12 Total
1 Water Station 410-P 28 28 28 28 112

2 Water Station 510-P 28 28 28 28 112
3 Water Station 610-P 28 28 28 28 112
Total Cost (1000 LE) 84 84 84 84 336

Annual Material Plan (PM + 20% CM)
System: A Water Pumping Station (4 units 3 Running & 1 Standby)
PM Levels Annual Materials

Policy # Maintainable Items
W M Q 6M A / Unit PM CM Total
1 Mechanical Seals (1) C C C R R 2 8 2 10
PM
2 Bearing (2) C C R 2 8 2 10
3 Shaft Sleeve C 1 1
4 Shaft C 1 1
5 Coupling C C 1 1
6 Impeller C C 1 1
7 Casing C C 1 1
RTF
8 Strainers C C 1 1
9 Valves C C C C 2 2
10 Electric Motor C C 1 1
11
12
Based on MTBF &
At least one item
C: Check R: Replace (safety stock)
Annual Material Plan (PM + 20% CM)

Months - 2018
# Equipment ID 1 2 3 4 5 6 7 8 9 1 11 12
0
- - 2 seal 2 seal 2 seal 2 seal
2 bear 2 bear 2 bear 2 bear
Maintenance Material
Seal 8+2 = 10 units & Bearing 8+2 = 10 units
W: (Running) M: (Running) Q: (Running) S: seal (1) A: seal (1) & bearing (2)

Maintenance Labor Force: (PM + 20% CM)
PM Weekly Load (man-hour)
System / Area Craft
Week #1 Week #2 Week #3 Week #4 …
Mech. 80 70 60 55
Area #1 Elec. 45 50 30 40
Inst. 15 20 10 30
Mech. 10 90 120 70
Area #2 Elec. 55 35 70 40
Inst. 30 30 30 25
Mech. 70 85 70 100
Area #3 Elec. 45 50 50 50
Inst. 25 20 20 15
… … … … … … …
Standard Working Hours (Policy) = 200 man-hour/month or 2000 man-hour/year
Based on this information , calculate the maintenance labor force.

Maintenance Labor Force: (PM + 20% CM)
System / Area Craft PM Weekly Load (man . hour)
#1 #2 #3 #4 …
Mech. 80 70 60 55
Area #1 Elec. 45 50 30 40
Inst. 15 20 10 30
Mech. 10 90 120 70
Area #2 Elec. 55 35 70 40
Inst. 30 30 30 25
Mech. 70 85 70 100
Area #3 Elec. 45 50 50 50
Inst. 25 20 20 15
… … … … … … …
Mech. 160 245 250 225
Weekly Totals Elec. 145 135 150 130
Inst. 70 70 60 70
Mech. 880 man-hr / (200 hr/month) = 4.4 *1.2 = 6 workers (3)
Monthly Totals Elec. 560 man-hr / (200 hr/month) = 2.8 *1.2 = 4 workers (2)
Inst. 270 man-hr / (200 hr/month) = 1.4 *1.2 = 2 workers (1)

(6) (1)
Work Network /
Orders Sequence
(5) (2)
Resource
Shutdown
Work / Job
Loading Planning Schedule
(4) (3)
Cost Resource
Plan Plan
Critical Resources
(Limited or High Cost)
Work Order / Job Planning
Case Study #1
Project: Major Maintenance Job: Mech. Maintenance
Activity Critical
Predecessors Resource & Duration
ID Resources
A - 8 man-hours
B - 12 man-hours
C A 2 (1 worker * 2 hours)
D C 23 man-hours
E B 4 (1 worker * 4 hours)
F D,E 7 man-hours
A 8 man-hours
Constraints: 2*4 = 8
Max. # workers = 5 workers 4*2 = 8
Cost Rate = 100 LE/man-hour Open Resources
Max. duration = 14 Hours (Lamp sum)
Based on this information; discuss

1) Network 2) Target plan 3) Cost profile 4) Resource loading

Case Study #1
Project: Major Maintenance Network / Logic diagram / Process Chart:
Job: Mech. Maintenance
A C D
Resource
ID Pred.
(Man-hours)
A - 8 man-hours
Start F Finish
B - 12 man-hours B E
C A 2 (1 worker * 2 hours)
D C 23 man-hours
E B 4 (1 worker * 4 hours) Optimal:
F D,E 7 man-hours Resources:
Constraints: Total Effort = 56 man-hours
Max. # workers = 5 workers Direct Cost = 56*100 = 5600 LE (Target)
Cost Rate = 100 LE/man-hour
Max. duration = 14 Hours Resources (man) 5 56/14 = 4
56/5 =
Based on this information; discuss Time (day) 14
11.5 = 12
1) Network 2) Target plan
3) Cost profile 4) Resource loading Importance Time Resource

(Critical Resources)
Hours
Hours
Man-
ID Pre.
hour 1 2 3 4 5 6 7 8 9 10 11 12 13 14
A - 8 3 2 3 3
B - 12 4 2 4 4 2
C A 2 2 1 1
D C 23 6 3 4 4 4 4 4
E B 4 4 1 1 1 1
F D,E 7 2 4 3
# of Workers 2 3 5 5 5 5 5 5 5 5 4 4 3
Cost Profile 200 300 500 500 500 500 500 500 500 500 400 400 300
Total Cost 5,600 LE
Constraints:
Max. # workers= 5 workers ( 100 LE/man-hour) Max. duration= 14 hours

Hours
Resource Loading
1 2 3 4 5 6 7 8 9 10 11 12 13 14
W1 A A A B B B E E E E - - -
W2 A A A B B B D D D D D F -
W3 - A A B B D D D D D D F F
W4 - - B B B D D D D D D F F
W5 - - B C C D D D D D D F F
# of Workers 2 3 5 5 5 5 5 5 5 5 4 4 3
Cost Profile 200 300 500 500 500 500 500 500 500 500 400 400 300
Total Cost 5,600 LE
Constraints:
Max. # workers= 5 workers ( 100 LE/man-day) Max. duration= 14 hours

Case Study #2
Activity Critical
Predecessors Resource & Duration Resources
ID
A - 8 man-hours
B - 12 man-hours
C A 2 man-hours
D C 23 man-hours
E B 4 man-hours
F D,E 7 man-hours
Constraints:
Max. # workers = 5 workers Cost Rate = 100 LE/man-hour
Max. duration = 14 hours Bonus / Delay = ±100 LE/hour


Case Study #3
Activity Critical
Predecessors Resource & Duration Resources
ID
A - 4 workers * 2 hours
B - 4 workers * 3 hours
C A 1 worker * 2 hours
D C 4 workers * 6 hours
E B 1 worker * 4 hours
F D,E 4 workers * 2 hours
Constraints:
Max. # workers = 5 workers Cost Rate = 100 LE/man-hour
Max. duration = 14 hours Bonus / Delay = ±100 LE/hour


Shutdown Down Planning
Case Study #4
Work
Predecessors Resource & Duration Critical
Orders ID
Resources
A - 2 (1 worker * 2 days)
B - 2 (1 worker * 2 days)
C - 5 man-days
D A,B 6 man-days
E C 8 man-days
F C 2 (1 worker * 2 days)
G D,E 4 man-days
Constraints:
Max. # workers = 4 workers Cost Rate = 1,000 LE/man-day
Max. duration = 8 Days Bonus / Delay = ±1000 LE/day


Project: Major Maintenance
Job: Mech. Maintenance
Network / Logic diagram / Process Chart:
W/o Resource
Pred. A D G
ID (Man-Days)
A - 2 (1 worker * 2 days)
Start B Finish
B - 2 (1 worker * 2 days)
E
C - 5 man-days
C F
D A,B 6 man-days
E C 8 man-days
F C 2 (1 worker * 2 days)
G D,E 4 man-days Optimal:
Constraints: Resources:
Total Effort = 29 man-days
Max. # workers = 4 workers
Direct Cost = 29*1000 = 29,000 LE (Target)
Cost Rate = 1,000 LE/man-day
Max. duration = 8 Days
Bonus / Delay = ±1000 LE/day Resources (man) 4 29/8=3.6=4
29/4 =
Time (Days) 8
Based on this information; discuss 7.25= 8
1) Network 2) Target plan
3) Cost profile 4) Resource loading Importance Time Resource

Man- Days
Days
ID Pre.
Days 1 2 3 4 5 6 7 8 9 10
A - 2 2 1 1
B - 2 2 1 1
C - 5 3 2 2 1
D A,B 6 3 3 2 1
E C 8 3 2 3 3
F C 2 2 1 1
G D,E 4 2 3 1
# of Workers 4 4 4 4 4 4 4 1
Cost Profile 4,000 4,000 4,000 4,000 4,000 4,000 4,000 1,000
Total Cost 29,000 LE
Constraints:
Max. # workers= 4 workers (1,000 LE/man-day) Max. duration= 8 Days

Days
Resource Loading
1 2 3 4 5 6 7 8 9 10
W1 A A D D D F F
W2 B B D D E E G
W3 C C D E E E G
W4 C C C E E E G G
# of Workers 4 4 4 4 4 4 4 1
Cost Profile 4,000 4,000 4,000 4,000 4,000 4,000 4,000 1,000
Total Cost 29,000 LE
Constraints:
Max. # workers= 4 workers (1,000 LE/man-day) Max. duration= 8 Days

Case Study #5
Work
Orders ID
Resources
A - 2 man-days
B - 2 man-days
C - 5 man-days
D A,B 6 man-days
E C 8 man-days
F C 2 man-days
G D,E 4 man-days
Constraints:


Case Study #6
Work
Orders ID
Resources
A - 1 worker * 2 days
B - 1 worker * 2 days
C - 3 workers * 2 days
D A,B 3 workers * 2 days
E C 4 workers * 2 days
F C 1 worker * 2 days
G D,E 2 workers * 2 days
Constraints:


Maintenance Work Order Form , for example
Area / Location: 410 TAG No.: 410-P-001 Equipment: Centrifugal Pump
Criticality: SCE Job Type: Annual PM Department: Mechanical
W/O Number: 2018-0027 W/o Priority : High Shutdown : Yes Work Permit: 1234
Planned Performance Feedback

Planned Job: Actual Job:
Job
Refer to MWI ……
Planned Maintenance Duration: Actual Maintenance Duration:

Planned Downtime: Actual Downtime:
Times
Planned Repair Time: Actual Repair Time:

Planned Start Date: / / 2018 Actual Start Date: / / 2018
Planned Finish Date: / / 2018 Actual Finish Date: / / 2018
Planned Manpower: Actual Manpower:
Resources
Planned Materials: Actual Materials:
Planned Tools: Actual Tools:
Comments:
Close Out: / / 2018 Reported by:

Planned Performance Feedback

Planned Job: Actual Job:
Job
Refer to MWI ……
Planned Maintenance Duration: Actual Maintenance Duration:

Planned Downtime: Actual Downtime:
Times
Planned Repair Time: Actual Repair Time:

Planned Start Date: / / 2018 Actual Start Date: / / 2018
Planned Finish Date: / / 2018 6 Questions? Actual Finish Date: / / 2018
Planned Manpower: Actual Manpower:
What? Job √
Resources
When? Schedule √
Planned Materials: Actual Materials:
How? Resources √
Planned Tools: √
Where? LocationActual Tools:
Comments:
Who? Responsible √
Feedback? √
Close Out: / / 2018 Reported by:
Work Order Priority
Low Medium High Very High
P4 P3 P2 P1
Planned Normal Critical Emergency
Overhaul (Routine or PM)
(2 Weeks) (Week) (Do Today) (Start Now)

(within 14 days) (within 7 days) (within 24 hours) (within 2 hours)
Low Medium High Safety Critical

Production Production Production Elements
losses losses losses (SCE)
Refer to ISO 14224

Overdue %
SCE
3) Execution Feedback
W/o Feedback
OK / Done / Complete
Quantitative Qualitative
“Measurable” “Comments”
 Indicators??
Close-out

Feedback for Maintenance Control (KPIs):
Objective: High Quality (RAMS) at Low Cost

Objective KPIs Feedback W/o
(Outputs)
Reliability
High
Quality Availability
Maintainability
(RAMS) Safety (SCE)
(Inputs) Critical Resources
Capacity (Operation Eff.)
Low
Cost Cost

Feedback for Maintenance Control (KPIs):
Objective KPIs Feedback W/o
System Reliability CM Downtime
MTBF seal Operating time
(Outputs) Reliability MTBF bearing #of failures
CM/PM seal # CM W/o
CM/PM bearing # PM W/o
High Availability System Availability PM & CM Downtime
Quality Actual PM W/o
PM Efficiency
Target PM W/o
Maintainability MTTR seal
Time to repairs
(RAMS) MTTR bearing
#of failures
MTTR seal & bearing
Safety Overdue for SCE #Overdue W/o for SCE
Actual man.hours /
(Inputs) Resources Labor Productivity
Target man.hours
Productive time
Capacity System OEE
Low Time losses
Cost Cost Maintenance Cost Rate
Maintenance cost / hour
Maintenance cost / unit
4) Control KPIs
KPIs Analysis
• Reliability Analysis
• Availability Analysis
• Maintainability Analysis
• Safety Analysis
• Resources Productivity
• Cost Efficiency Good Data = Good KPIs
• …. etc.
Bad Data = Bad KPIs
Time Analysis
Maintenance Time Down Time
Repair Logistic Planned Unplanned

Time Time
PM CM
Down Time Down Time
MTTR MTBF
Maintainability Reliability
Labor Utilization Availability

Work Order Status
Completed Waiting
On Schedule Overdue Backlog Cancelled

PM
Efficiency Overdue % Routine maintenance
for non-critical
equipment
Why?
(Cause, root cause, consequence, … etc.)
Mean Time to Repair (MTTR) & Mean Time to Maintain (MTTM)
Repair Time Repair Time Repair Time
Mean Time to Repair (MTTR) (CM Only):

MTTR = Total Repair Time / Number of Repairs
MTTR = Total CM Repair Time / Number of CMs
Mean Time to Maintain (MTTM) (PM Only):

MTTM = Total PM Maintenance Time / Number of PMs
Mean Time Between Failure (MTBF)
Based on MTBF:
CM   PM
Policy RTF (CM Only):

MTBF = Total Operating Time / Number of Failures
t0 MTBF
Policy PM & CM:
MTBF = Total Time Between Failures / Number of CMs
Check:
MTBF ≤ PM Interval
Policy PM & CM:
MTBF ≈ Total Operating Time / Number of (CMs + PMs)
CM/PM Analysis
Unplanned Maintenance
Corrective Run To Fail

Maintenance (RTF)
(CM)
(Service Call)
(Minor CM)
Minor CM Major CM
(Downtime)
CM / PM Ratio (#, hours, downtime, man-hour, cost, … , overall)

Operational Availability & Reliability & Utilization Analysis
Standard time (TT)

A
Planned (target) time (PT) PM
R
Available time (AT) CM
U
Operating (used) time (OP) Downtime
Waiting
U Op. Delay
S/B
A= Equipment Availability = AT/TT

= Available time / Total Time
PM = Planned downtime
= (Total Time – Downtime) / Total Time
CM = Corrective downtime
= (OP + S/B) / (OP+S/B+PM+CM)
S/B=Standby time
R= Equipment Reliability = AT / PT
OP = Operating time
= (OP+S/B) (OP + S/B + CM)
AT = Available Time
U= Equipment Utilization
PT = Planned Time
= OP / AT or = OP / TT
Maintenance Control (KPIs):
Objective: High Quality (RAMS) at Low Cost
Objective KPIs Actual Target Recommendations
System Reliability
MTBF seal
(Outputs) Reliability MTBF bearing
CM/PM seal
CM/PM bearing
High System Availability
Availability
Quality
PM Efficiency
Maintainability MTTR seal

(RAMS) MTTR bearing
MTTR seal & bearing
Safety Overdue for SCE
(Inputs) Resources Labor Productivity
Capacity System OEE

Low
Maintenance Cost Rate
Cost Cost
Information For Annual Control (KPIs):
The maintenance information for a water pumping
station is as follows:
System: A Water Pumping Station Manpower:
(4 units 3 Running & 1 Standby) 4 Workers
Working Conditions: 24 hours/day 2000 h/y
Annual PM Work Orders Weekly Monthly
(2000 RH) (4000 RH) (8000 RH)
Cleaning Cleaning Check … Check …
Cleaning
Maintenance Task Check … Check … Check … Replace seal
Check …
Check … Check … Replace seal Replace bearing
Actual PM W/o
Total PM Downtime
Total maintenance time
Manpower
Annual CM Work Orders Seal Failure Bearing Failure ….

CM Work Orders
Time Between Failure; hours
Repair Time; hours
CM Downtime; hours
Total Repair Time
RCM
Manpower Maintenance Management Best Practice – Dr. Attia Gomaa - 2018 108
Annual PM Work Orders Weekly Monthly
(2000 RH) (4000 RH) (8000 RH)
Cleaning
Maintenance Task Check … Check … Check … Replace seal
Check …
Check … Check … Replace seal Replace bearing
Actual PM W/o 132 26 6 3 3
Total PM Downtime - - - 24 36
Total maintenance time 160 65 24 36 51
Annual CM Work Orders Seal Failure Bearing Failure

CM Work Orders 3 2 Based on this
Time Between Failure; hours 3400, 3200, 3600 6400, 6200 information; discuss
Repair Time; hours 33 30 the Maintenance
CM Downtime; hours 30 25 KPIs.
Total Repair Time 36 30
RCM
Manpower 2 Mech.
Maintenance + 1 Elec.
Management 3 Mech.
Best Practice + 1Gomaa
– Dr. Attia Elec. - 2018 109
The maintenance information for a water
pumping station is as follows:
System: A Water Pumping Station
(4 units 3 Running & 1 Standby)
Working Conditions: 24 hours/day
KPIs
Current Future
Feedback Feedback
Reactive Analysis Proactive Analysis

1. CM / PM • Overdue of SCE
2. PM Efficiency • Canceled of SCE
3. MTTR & MTTM • Operation Efficiency
4. MTBF • System OEE
5. Availability • Maintenance Cost Rate
6. Reliability • .....
7. Labor Productivity
CM / PM (#/#):
Annual PM Performance:
Cleaning
Maintenance Task Check … Check … Check … Change seal
Check …
Check … Check … Change seal Change bearing
Number of Actual PM W/o 132 26 6 3 3
Annual CM Performance:
CM Task Seal Failure Bearing Failure
Number of CM W/o 3 2
Item Unit Seal Bearing

Actual CM / PM 5/6 = 83% 3/6 = 50% 2/3 = 67%
Target CM / PM < 20% < 20% < 20%
Recommendations Updating PM RCFA RCFA
PM Efficiency: (PM% on time) or PM Compliance %
Planned Frequency / Unit
0 1 2 3 4 5 6 7 8 9 10 11 12
M M Q M M M M Q M M
S
Annual PM Performance: A
Weekly Monthly
(2000 RH) (4000 RH) (8000 RH)
Cleaning
Maintenance Task Check … Check … Check … Change seal
Check …
Check … Check … Change seal Change bearing
160 32 8 4 4
Planned PM Frequency
200 8
Running Shutdown
Item Total PM
Maintenance Maintenance
PM Efficiency 170/208= 82% 164/200= 82% 6/8= 75%
Backlog % 18% 18% 25%
Target PM Eff. 100% 100%
Recommendations Updating PM RCFA
Mean Time to Maintain (MTTM) & Mean Time to Repair (MTTR):
Mean Time to Maintain (MTTM): Assume; PM downtime = PM Maintenance time

Cleaning
Maintenance Task Check … Check … Check … Change seal (1)
Check …
Check … Check … Change seal (1) Change bearing (2)
Total PM Downtime, hours - - - 24 36
MTTM 8 12
Mean Time to Repair (MTTR): Assume; CM downtime = repair time

Annual CM Performance:
CM Task Seal Failure Bearing Failure
Number of CM W/o 3 2
Total CM Downtime, hours 30 25
MTTR 10 12.5
Mean Time Between Failure (MTBF):
Standard PM Hours: Annual CM Performance:
CM Work Orders 3S , 2B
Replace Replace
Item Time Between Failure; S (3400,3200,3600)
Seal Bearing
hours B (6400,6200)
Semi-
PM Level Annual Repair Time; hours 33 , 30
Annual
CM Downtime; hours 30S , 25B
Standard
4000 8000 CM Labor; man-hours 250
PM Hours
Item: S:Seal B:Bearing
MTBF = Total Operating Time / Number of Failures  RTF
Seal (S)  (3400+3200+3600) / (3 CMs) = 3400 hours/failure

Bearing (B)  (6400+6200) / (2 CMs) = 6300 hours/failure
Unit  (3400+3200+3600+ 6400+6200) / (5CMs)= 4560 hours/failure
Item Unit Seal Bearing

MTBF 4560 3400 6300
Target MTBF Semi-Annual Semi-Annual Annual
Recommendations Updating PM RCFA RCFA
Operational Availability & Reliability (Based on Downtime)
Feed Water Pump Station  4 Units (3 Running &1 standby)
Standard Time = 8760*3 = 26280 hour/year,
PM Downtime = 60 hours , CM Downtime= 55 hours , Total Downtime = 115 hours
Standard time (TT) = 26280

A
Target time (PT) = 26280 – 60 = 26220 PM
R 60
Available time (AT) = 26220 – 55= 26165 CM
55
D
TT = Calendar Time 115
AT = Available Time
PT = Planned Time
D = Total Downtime = 115 hours
PM = Planned Downtime
CM = Corrective Downtime A= Equipment Availability = AT/TT
D = Total Downtime
= 26165 / 26280 = 99.56%
R= Equipment Reliability = AT / PT
= 26165 / 26220 = 99.79%
(R ≥ A ≤100%)
Maintenance Control (KPIs)
Objective KPIs Actual Target Rec.
System Reliability 99.79% 99.9%

MTBF seal 3400 4000
Reliability MTBF bearing 6300 8000
(Outputs) CM/PM seal 50% 20%

CM/PM bearing 67% 20%
Availability System Availability 99.56% 99.9%
High
Quality PM Efficiency 82% 90%
Maintainability
MTTR seal 10 8
Repair time
MTTR bearing 15 12
Safety Overdue for SCE - - Finish date
(Inputs) Resources Labor Productivity 12.6% 15% Man-hour
Capacity System OEE - - Time analysis

Low
Cost Cost Maint. Cost Rate
Feedback
- - LE / ton
Unit P1 P2 P3 P4 Total (4 units)
Actual Operating Time; hours
Running PM Work Orders
Semi-Annual PM Work Orders (S)
Semi-Annual PM Downtime; Hours
Annual PM Work Orders (S,B)
Annual PM Downtime; Hours
PM Labor; man-hours
Annual CM Performance: Item: S:Seal B:Bearing
CM Work Orders
Time Between Failure; hours
Repair Time; hours
CM Downtime; hours
CM Labor; man-hours
Actual Operating Time; hours 6900 6300 6200 6880 8760*3
Running PM Work Orders 50 34 35 45 164
Semi-Annual PM Work Orders (S) 1 - - 2 3
Semi-Annual PM Downtime; Hours 9 - - 15 24
Annual PM Work Orders (S,B) 1 1 1 - 3
Annual PM Downtime; Hours 14 10 12 - 36
PM Labor; man-hours 340 270 290 300 1,200
Annual CM Performance: Item: S:Seal B:Bearing
CM Work Orders - 2S 1S , 1B 1B 3S , 2B
(3400,3200,3600)
Time Between Failure; hours - 3400,3200 3600,6400 6200
(6400,6200)
Repair Time; hours - 10,12 11,14 16 33 , 30
CM Downtime; hours - 9,10 10,14 12 30S , 25B
CM Labor; man-hours - 70 100 80 250
Total (calendar) time (TT) = 8760

KPIs Report
A
Pump #1 Availability Analysis
Planned (target) time (PT) = 8746
14
R PM
Available time (AT) = 8746
0
CM
U Operating (used) time (OP) = 6900 1846 Downtime
S/B
Total Planned Unplanned Total Available Standby Operating

Hours downtime downtime downtime time time time
8760 14 0 14 8746 1846 6900
Availability % Reliability % Utilization %

99.84% 100 % 78.76 %

KPIs Report
A
Planned (target) time (PT) = 8750
10
R PM
Available time (AT) = 8731
19
CM
U Operating (used) time (OP) = 6300 2431 Downtime
S/B

8760 10 9+10 29 8731 2431 6300

99.67% 99.78 % 71.91 %

KPIs Report
A
Planned (target) time (PT) = -
-
R PM
Available time (AT) = -
-
CM
U Operating (used) time (OP) = - - Downtime
S/B


KPIs Report
A
Planned (target) time (PT) = -
-
R PM
Available time (AT) = -
-
CM
U Operating (used) time (OP) = - - Downtime
S/B

Pump # Availability % Reliability % Utilization %
P1 99.84% 100 % 78.76 %
P2 99.67% 99.78 % 71.91 %
P3
P4
Figure
Annual KPIs Report For Top Management
Facility / Site
Top
(Facility)
Level I
Middle
(Systems)
Level II
Turbine Boilers

KPIs Report KPIs - Level I
Availability
Plant
KPIs Report
Availability
Equipment
Critical
Performance
Production
Efficiency
Page 1/6
KPIs - Level I
KPIs Report
Accumulative Plant Availability
Page 2/6
KPIs - Level II
Accumulative Boiler Availability

KPIs Report
Page 3/6
KPIs - Level II
Total (calendar) time (TT)
Accumulative Boiler Availability A

Planned (target) time (PT)
KPIs Report
PM
R
Available time (AT) CM
U Operating (used) time (OP) S/B Downtime

9504 400 180.5 580.5 8923.5 0 8923.5

93.89 98 93.89
Page 4/6
KPIs - Level II
Top Critical Equipment (Accumulative Down Time)

KPIs Report
Page 5/6
KPIs - Level III
PM % ↑
Planned Maintenance (%)
Reliability Analysis for Boilers
MTBF (Hr)
KPIs Report
92%
MTTR (Hr)
85 %
75 %
70 % 7,550
7,114
5,650
6,496
10.9
6.3 6.3 5.5
Year
2011 2012 2013 2014
Page 6/6
5) Improvement
1. Failure Analysis
1) Focus Group
• Trouble Shooting
• Root Cause Failure Analysis (RCFA)
• Reliability Prediction Analysis
• Failure Mode Effect Analysis (FMEA) 2) Information &
Knowledge
• Fault Diagnostics
3) Equipment
2. Update PM Program Design
4) Manufacturing
3. Update Work Orders Process
5) Operating
Conditions
Root Cause Failure Analysis (RCFA)
Cause-and-Effect Diagram or Fishbone diagram

Environmental Manpower Method
Failure
Measurement Machine Materials
Continuous Improvement Cycle
Root Causes of Pump Failures
• Lack of maintenance (clean, check, Replace, ... etc.) > 30%
70% Maintenance
Management
• Operating Conditions (flow rate, head, speed, … etc.) > 20%
• Human errors (not qualified, under stress, … etc.) > 10%
• Unsafe conditions (Near-miss) > 5%
• No Information (references, manuals, history, … etc.) > 5%
• Poor quality of spare parts (low cost, … etc.) >20%

• Poor design (selection, location, … etc.) >10%
• Others <10%
Pump Reliability Curve
BEP: Best Efficiency

Point  PM MTBF
Check Operating Conditions Valves
Pumps
Motors
Gap Analysis …. etc.
BEP
Actual Operating ± 5% Standard Operating
Conditions ± 10% Conditions
(Process) ± 20% (Manual)
± 30%
…. BEP: Best Efficiency
Point  PM MTBF
> 20%
Failures
Actual Range: Best:
• Flow Rate: (40 to 50) m3/hour • Flow Rate: 44 m3/hour
• Pressure: (8.5 to 9.5) Kg/cm2 • Pressure: 8.9 Kg/cm2
Main Failures: Source: CM Work Orders
Item Main Failures Main Failure Modes

Bearing Bearing Failure
Functional Failures
No Flow
Potential Failures
Seal Seal Leakage

Insufficient flow
Shaft Shaft Wear
Impeller Cavitation On Impeller Insufficient head
Coupling Misalignment High Power Consumption
Motor Overheating Motor High Vibration
Valves Valve Failure
High Noise
Strainer Strainer Failure
….. ….. …..
PUMP Trouble Shooting
1- No Flow
2- Insufficient Flow
3- Insufficient Head
4- High Vibration and Noise
5- Leakage
6-
Fault detection Matrix
7-
Problem Causes
X 1- Pump not primed
X X X 2- Speed too low
X X X 3- Not enough NPSH
X X X 4- Impeller Blocked
X X 5- Damaged Impeller
X 6- Discharge head too high
X 7- Misalignment
X 8- Bearing failure
X 9- Foundation not rigid
X 10- Air or gas in liquid
X 11- Mechanical seal failure
12-
Failure Analysis Record:
System: Steam System Equipment: Feed Water Pumps Criticality: High
Equip. Date of Work Date of Failure Repair Maint. Date

Comments
ID Failure Order # Last failure Description Actions Leader Completed
Seal Change
Failed seal
High Change
Vibration bearing
History: 5 years (2009 – 2013)
PUMP MTBF
Reliability
Motor MTBF
Reliability
Through root cause analysis, better lubrication practices, vibration and oil analysis, an
improvement in mean time between failures (MTBF) for both pumps and motors was achieved.
History: 5 years (2009 – 2013)
CM Work Orders
Reliability
Problem Analysis Using Pareto Chart
(Rule 80/20)
Cause-and-Effect Diagram (Main Items)
…. Valves Coupling
Failures Failures
Pump
Station
Failures
Strainers Motor Pump

Failures Failures Main
Failures
Causes
…. Valves Coupling
Failures Failures
Operating
Conditions Coupling
Materials
Assembly
Method Pump
Station
Seals Failures
Bearing
Stator
Bearing
Rotor Shaft &
Operating Sleeve
Conditions Impeller
Flow Meter Motor Pump Unit

Failures Failures Main
Failures
Causes
…. - Bearing
Failures Failures
Pump
Unit
Failures
- -
Failures Failures Seal Failures Main
Causes
Cause-and-Effect Diagram (5 M’s + E), for example
…. - -
Failures Failures
Motor
Failures
- -
Failures Failures Bearing Failures Main
Causes
Main Pump Failures: Source: CM Work Orders
Mechanical Seal Bearing Coupling
Sleeve Impeller
Root Cause Analysis
RCFA Form (Level 1), for example
Problem Definition: Drawings:

Plant: Date:
Equipment: W/O Number:
Situation: Policy:
History:
Must be customized
Failure Analysis:
Failure Control:
Future Recommendations:
Must be customized
Problem Definition: Drawings:

Plant: LAB Date: 19/3/2018
Equipment: PUMP 2A W/O Number: 7100 / …..
Situation: Repeated Bearing Failure Policy: Annual

History: New Set installed in May 2017
Analysis:
# Main Root Causes Main Actions
1 Misalignment 1- Check alignment method 2- Check manpower errors
2 Oil Conditions 1- Check oil types 2- Check oil analysis interval
3 Bearing Material 1- Check material type 2- Check inventory conditions
Control:
# Main Recommendations Responsibility
Advanced training program in alignment
1 1- HR Dep. 2- Maintenance leader
techniques
2 Apply laser technique 1- Maintenance leader 2- Material Dep.
Cause-and-Effect Diagram or Fishbone diagram
Environmental Manpower Method

Site Unsafe
Number of MWI
conditions acts Assembly
Unsafe workers
method
conditions
Job plan
Culture Training
Bearing
Failure
Process Life time Inventory
parameters conditions
Tools Safety
accuracy Material
Operating conditions Material type
Condition
conditions manufacturing
monitoring
Measurement Machine Materials
Based on this analysis , Update PM Program

Bearing Failure Causes
Reliability Analysis
Probability of zero failures during standard time according
to standard working conditions.
Must be planned for, designed in both in terms of the initial product
and in maintenance of that product
Customer
satisfaction
Reliability is a dynamic aspect of Quality.

Reliability is Performance Over Time
Reliability – Performance Over Time R(t)  f (MTBF)
Failure Rate = l = 1 / MTBF
R(t) = e- lt
R(t) = exp(-λt) ≈ 1 – λt
[when λt is less than 0.001]
In this formula, the failure rate, λ, is

assumed to be constant with the age
of the component.
• MTBF (mean time between failure) 1

MTBF 
= the amount of time between failure of a repairable product l (t )
• MTTF (mean time to failure) 1
= the amount of time between failure of a non-repairable MTTF 
l (t )
(i.e., must be replace) product
Reliability Prediction Analysis
Failure Rate = l = 1 / MTBF Exponential distribution
Reliability = R(t) = e- lt Constant Failure Rate
Reliability %
t2 t3 t4
Lower Limit
(0 to 50%) t1
Based on
Criticality
Running Time
Feed Water Pump:
Coupling
Motor Pump
Schematic diagram
of centrifugal pump:
1. Inlet valve;
2. Vacuum gauge;
3. Centrifugal pump;
4. Torque meter;
5. Motor;
6. Pressure gauge;
7. Flow meter; and
8. Outlet valve.
…
Reliability Prediction Analysis: Feed Water Pump ##
Coupling
Motor Pump
History (5 years):
Working Condition = 20,000 Running Hours
Motor Coupling Pump

Number of 2 5
3
failures (bearing) (3 seal & 2 bearing)
Based on this information, calculate the following:

1. MTBF & Failure Rate
2. Reliability after 1000, 2000, 4000, 8000 hours
3. Cause-and-Effect Diagram for Pump Failure
4. Recommendations to update the PM Program
Reliability Prediction Analysis:
Failure Rate =
Exponential
Coupling l = 1 / MTBF distribution
&
Motor Pump Reliability = Constant
Failure Rate
R(t) = e- lt
Analysis Motor Coupling Pump System

Number of failures 2 3 5
MTBF 10000 6666.7 4000.0
Failure Rate 0.00010 0.00015 0.00025
Reliability after t=1000 hours 90.5 86.1 77.9 60.7
Reliability after t=10000 hours
Reliability %
Coupling 100
90
Motor Pump
80
70
Time;
Motor Coupling Pump System
hours 60
0 100 100 100 100 50
1000 90.5 86.1 77.9 60.7 40
2000 81.9 74.1 60.7 36.8 30
4000 67.0 54.9 36.8 13.5 20
8000 44.9 30.1 13.5 1.8 10
10000 36.8 22.3 8.2 0.7 0

0 2000 4000 6000 8000 10000
Recommendations: Motor Coupling
Improve PM Pump Policy by 20% Pump System
Reliability %
Coupling 100%
90%
Motor Pump
80%
Time; 70%
Motor Coupling Pump System
hours
60%
0 100% 100% 100% 100%
50%
1000 90.5% 86.1% 81.9% 63.8%
40%
2000 81.9% 74.1% 67.0% 40.7%
30%
4000 67.0% 54.9% 44.9% 16.5%
20%
8000 44.9% 30.1% 20.2% 2.7%
10%
10000 36.8% 22.3% 13.5% 1.1%
0%
0 2000 4000 6000 8000 10000
Recommendations:
Motor Coupling
Update PM Program
Pump System
Cause-and-Effect Diagram for Pump Failure; for example
Pump Failure
Main Failures: Recommendations to update the PM Program:
Pump Unit: (65%) Pump Unit:
• Mechanical Seal Failure 30% •
• Bearing Failure 25% •
• Shaft & Sleeve Failure 6% •
• Impeller Failure 4% •
Coupling: Coupling:
• Coupling Failure 16% •
Motor: Motor:
• Motor Failure 10% •
Valves: Valves:
• Valve Failure 5% •
Strainer: Strainer:
• Strainer Failure 4% •
Item: Gate Valve
Total Number of Units = 10 Units
History (5 years):
Number of failures = 5 units
Based on this information, calculate the following:

1. MTBF & Failure Rate
2. Reliability after 1000, 2000, 4000, … , 8000 hours
3. Cause-and-Effect Diagram for Valve Failure
4. Recommendations to update the PM Program
Cause-and-Effect Diagram (5 M’s + E)
Environmental Machinery Material
Valve
Failure
Measurements Method Manpower Main

Causes
Pressure
Gauge
Failure
Measurements Method Manpower
Flow
Meter
Failure
Measurements Method Manpower Main

Causes
Torque
Meter
Failure
Measurements Method Manpower
Failure Mode Effect Analysis (FMEA) for Centrifugal Pump:
A Proactive tool to minimize the risk of failure and improve reliability
Failure
Function Failure Cause Failure Effect Recommendations
Mode
Check misalignment
No flow Overloaded motor Motor failure
Check motor
Fluid Flow
Insufficient Cavitation on impeller Check impeller
Pump low efficiency
flow Insufficient NPSH Check NPSH
Insufficient Cavitation on impeller Check impeller

Fluid Head Pump low efficiency
head Insufficient NPSH Check NPSH
Power High Power Check misalignment
Overloaded motor Motor failure
Consumption Consumption Check motor
Failure Mode Effect Analysis (FMEA) for Centrifugal Pump:
A Proactive tool to minimize the risk of failure and improve reliability
Failure
# Components Failure Cause Failure Effect Recommendations
Mode
Mechanical Seal Fails - Fluid leakage - Check seal
1 Leakage
Seal Poor Maintenance - Losses of pumping efficiency - Material selection
- Check misalignment
- Excessive pump vibration
Bearing Fails - Check bearing
High - Increased in shaft radial
2 Pump Bearing Bearing temperature temperature
Vibration movement
Poor Maintenance - Check bearing
- Eventual pump shutdown
vibration
- Vibration
High Shaft wear
3 Shaft - Possible bearing damage - Check shaft
Vibration Poor Maintenance
- Eventual coupling failure
Cavitation - Pump low efficiency
Insufficient - Check impeller
4 Impeller Insufficient NPSH - Vibration
head - Check NPSH
Poor Maintenance - Reduce in suction power
High - Bearing failure - Check misalignment
5 Coupling Coupling damage
Vibration - Motor failure (laser alignment)
- Check misalignment
Bearing Fails - Check bearing
High - Motor Shutdown
6 Motor Bearing Bearing temperature temperature
Vibration - Pump Shutdown
Poor Maintenance - Check bearing
vibration
Fault Diagnostics for Electrical Motors
Fault Diagnostics for Electrical Motors
Update PM Program / Unit (Maintenance Manual & Experience):
Cleaning Cleaning Cleaning Cleaning Cleaning
Check operation Check operation Check operation Check operation Check operation
Check seals Check seals Check seals Check noise Check noise
Check noise Check noise Check noise Check valves Check valves
Check oil Check oil Check oil Check vibrition
Check valves Check valves Check vibrition Check coupling
Check
Check vibrition Check coupling Check impeller
Job
Check coupling Check impeller Check casing

Check casing Check shaft
Check strainers Check strainers
Check motor Check motor
- - - Replace seal Change Oil

Replace Replace seal
Replace bearing
Maint. Type Running Running Running Shutdown Shutdown
Downtime
- - - 8 12
Time
hours / order
Maint. Time
hours/order 1 2 3 10 15
Resources
Man . hour 2 4 6 30 60
Vibration device Vibration device Vibration device
Special Tools
Laser alignment Laser alignment Laser alignment
RCMEq.
Service Maintenance Management Best Practice – Dr. Attia Gomaa - 2018 175
Annual PM Program (8000 RH) Planned Feedback
Cleaning
Check operation
Check noise
Check valves
Check vibrition
Check Check coupling
Check impeller
Job
Check casing
Check shaft
Check strainers
Check motor
Change Oil
Replace (Spare Parts) Replace seal
Replace bearing
Maintenance Type Shutdown
Downtime hours / order 12
Time
Maintenance Time hours/order 15

Manpower 3 Mech. + 1 Elec.
Resources
Effort (Man . Hour) 60

Special Tools Vibration device
Service Eq. -
Main References:
References:
• J. Moubray, Reliability Centered Maintenance, Butterworth-Heinemann, Oxford, 1997.

• Charles E. Ebeling, An Introduction to Reliability and Maintainability Engineering,
Waveland Press, Inc., 2005.
• Elsayed, A. Elsayed, Reliability Engineering, Addison Wesley, 1996.
• MIL-P-1629 “Procedures for performing a failure mode, effects and criticality analysis
• Nicholls, David B., System Reliability Toolkit, DoD Reliability Information Analysis
Center (RIAC), 2005
• O'Connor, Patrick D. T., Practical Reliability Engineering, 4th ed., Wiley, 2002
• http://www.fmeca.com/
Made in Egypt - ‫صنع في مصر‬
‫ أحفظ مصر وأهل مصر من كل سوء – اللهم أمين‬- ‫اللهم يا حفيظ‬
Thank you for your attention! Useful Science For
the Sake of Allah
Suggestions Comments
‫اللهم تقبل هذا العلم‬
Questions
Copyrights of this file & More information:
Dr. Attia Gomaa

Industrial Engineering Professor & Consultant
Mechanical Eng. Department – Shoubra Faculty of Eng. - Benha University
& Engineering and Science Services - American University in Cairo
attiagomaa@yahoo.com or attiagomaa@aucegypt.edu
Tel: 01222738497

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Dr. Attia Gomaa

Facebook: Attia Gomaa & Group: Maintenance Management – Dr. Attia

RCM December 2018

1. Maintenance Types & Policies

RCM Maintenance Management Best Practice – Dr. Attia Gomaa - 2018 2

This is an Open Discussion Course:

– Share Knowledge ‫– تبادل المعرفة‬

– Share Best Practices ‫– تبادل التجارب الجيدة‬

– Share Questions ‫– تبادل األسئلة‬

Remember … You can’t do it alone!

 Preventive Maintenance (Planned Maintenance)

 Breakdown Maintenance (Unplanned Maintenance)

RCM Maintenance Management Best Practice – Dr. Attia Gomaa - 2018 4

Planned (What? When? How?) Unplanned

RCM Maintenance Management Best Practice – Dr. Attia Gomaa - 2018 5

RCM Maintenance Management Best Practice – Dr. Attia Gomaa - 2018 6

Maintainability Resource Utilization

Direct costs Downtime losses

RCM Maintenance Management Best Practice – Dr. Attia Gomaa - 2018 8

Degree of Preventive Maintenance

RCM Maintenance Management Best Practice – Dr. Attia Gomaa - 2018 9

Maintenance Cost = (20% to 30%) from Life Cycle Cost

RCM Maintenance Management Best Practice – Dr. Attia Gomaa - 2018 10

Strategy is a systematic method

Strategy is a high level plan to

Your success as a manager depends on making a common

RCM Maintenance Management Best Practice – Dr. Attia Gomaa - 2018 12

RCM Maintenance Management Best Practice – Dr. Attia Gomaa - 2018 14

• Lack of maintenance (clean, check, Replace, ... etc.) > 30%

• Poor quality of spare parts (low cost, … etc.) >20%

RCM Maintenance Management Best Practice – Dr. Attia Gomaa - 2018 15

• L (Lubrication Task) - Replacement of a lubricant based on

• OC (On Condition Task) - Periodic or continuous inspection

• HT (Hard Time Task) - Scheduled removal of an item or a

• FF (Failure Finding Task) - A preventive maintenance task

RCM Maintenance Management Best Practice – Dr. Attia Gomaa - 2018 16

The replenishment of consumable materials that are depleted during

The scheduled lubrication of a component (usually based on the

Periodic or continuous inspection designed to detect a potential failure

Scheduled removal of an item or a restorative action

A preventive maintenance task performed at a

Efficiency Condition based Temperature

RCM Maintenance Management Best Practice – Dr. Attia Gomaa - 2018 22

RCM Maintenance Management Best Practice – Dr. Attia Gomaa - 2018 25

Failure Mode: High Temperature > 80 o C

Good Early Hidden Risk

Normal Failure Failure Engine

PM W/O Call for Call for B/d

Planned Planned Planned Unplanned

RCM Maintenance Management Best Practice – Dr. Attia Gomaa - 2018 32

Low Medium High / Very High

RCM Maintenance Management Best Practice – Dr. Attia Gomaa - 2018 34

Failure-Based - Asset Management

Long Term Continues Improvements  Teamwork Project (Maintenance, Operation, Safety)

RCM Maintenance Management Best Practice – Dr. Attia Gomaa - 2018 36

RCM Maintenance Management Best Practice – Dr. Attia Gomaa - 2018 37

RCM Maintenance Management Best Practice – Dr. Attia Gomaa - 2018 38

Discover hidden failures

Minimize the risk of

RCM Maintenance Management Best Practice – Dr. Attia Gomaa - 2018 39

Identification of hazards and

RBM / Determination of best maintenance Keep system function &