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SECTION 2
EFFECTIVE MAINTENANCE
MANAGEMENT
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CHAPTER 2.1
PRINCIPLES AND PHILOSOPHY
William N. Berryman
Engineering Consultant
Morgan Hill, California
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
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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, but it usually equates to additional cost of repair
due to its catastrophic nature.