Maintenance Strategies

Dr David Baglee
Faculty of Applied Sciences

ATF 205
Background
► Maintenance strategy is becoming a more
important issue
► Today machines are integrated
► Very little inventory stock held
► Automation of processes increasing
► Downsizing of workforce
Hidden Losses
Labour
Visible Costs
Materials

Breakdowns
Plant Trips
Hidden Losses
Operability
Reduced
Throughput
Restart Losses
Poor Quality
Poor Integrity
Low Morale
Maintenance Strategies
► Reactive Maintenance (1)
► Preventive Maintenance (2)
► Conditional Maintenance
► Predictive Maintenance (3)
► Total Productive Maintenance (TPM)
► Reliability Centred Maintenance (RCM)
Reliability Domains
Reliability Centered Maintenance

Total Productive Maintenance

RELIABILITY %

Predictive Maintenance

Planned Maintenance

Reactive Maintenance

MAINTENANCE EXPENSE
Reactive Maintenance
► Allow machinery to run to failure
► Traditionally the exclusive maintenance mode
until fairly recently
► Continues to be the predominate method of
maintenance
► Many major industrial companies still operate
in this mode
► Repair or corrective action is taken after the
fault has occurred
Advantages
► Low direct costs
► Less staff required
► Appropriate for certain
applications
Disadvantages
► High costs due to unplanned
downtime of equipment
► Increased labor costs,
especially if overtime is
needed
► Costs involved with repair or
replacement of equipment
► Possible secondary
equipment or process
damage from equipment
failure
► Inefficient use of staff
resources
► Does not support the true
definition of maintenance
Preventive Maintenance
► Actions that detect, prevent, or mitigate
degradation of a component or system
► Aims to sustain or extend useful life by
controlling degradation to an acceptable
level.
► Actions performed periodically prior to
functional failures to achieve desired safety or
reliability levels.
Preventive Maintenance
►A step forward from reacting to breakdowns
to preventing breakdowns:
 Pioneered by the U.S. Navy.
 Analogous to an automobile schedule of
maintenance.
 Time intervals based on manufacturer
recommendations and machinery history
experience.
Preventive Maintenance
► Scheduled maintenance activities are based
on specific time intervals
 Calendar days
 Run time
 Parts produced

► Includes routine tasks such as:

 Changing oil
 Replacing filters
 Greasing bearings
 Instrument calibration
Preventive Maintenance
► Includes measurement of degradation prone
areas for rapid changes in out-of-tolerance
conditions.
 Wear rings
 Alignment
 Shaft end play
► Useful against age related modes of failure:
 Wear
 Fatigue
 Corrosion
Advantages Disadvantages
► Cost effective in many ► Catastrophic failures still
capital intensive or likely to occur.
potentially high impact ► Labor intensive.
processes. ► Performance of
► Flexibility allows for the unneeded maintenance.
adjustment of ► Incidental damage to
maintenance periodicity. components through
► Increased component poor maintenance
life-cycle. practices.
► Energy savings.
► Reduced equipment or
process failures.
Conditional Maintenance
► Maintenance actions conducted as result of a
specific condition, or as a result of specific
circumstances or events.
 Examples of Conditional Inspections
 Aircraft hard landing
 Unscheduled disassembly
 Power Interruption
 Over/Under Voltage
 Lightning strike
 Over stress
 Unscheduled or scheduled shut-down
Predictive Maintenance
► Measurements that detect the onset of a
degradation mechanism thereby allowing
causal stressors to be eliminated or controlled
prior to any significant deterioration in the
component physical state.
► Results indicate current and future functional
capability.
► Involves use of specialised equipment to
monitor the condition of machines (Vibration,
Oil Analysis, Thermography, Acoustic
Emission, etc)
Predictive Maintenance
► Schedule maintenance activities when
mechanical or operational conditions warrant
to repair or replace deteriorated equipment
before obvious problems occur.
► Allows assessment of whether equipment will
fail during some future period
► Hence indicates best time to perform repairs
or maintenance
Advantages Disadvantages
► Increased component ► Increased investment in
operational life/availability diagnostic equipment
► Allows for pre-emptive
corrective actions ► Increased investment in
training of staff
► Reduced equipment or
process downtime
► Savings potentials not readily
► Decreased costs for parts seen by management
and labor
► Better product quality
► Improved worker and
environmental safety
► Improved worker morale
► Energy savings
Total Productive Maintenance
► JIT based approach
► Workers perform preventive maintenance on the
machines they operate
► Skilled maintenance personnel train the operators
and develop ‘one-point lessons’.
► Maintenance department moves from a ‘fire-fighting’
mode to a prevention mode & re-engineering
► Restore deteriorated equipment through
Improvement-Related Maintenance.
► Identify design weaknesses and improve equipment
► Preventive (equipment manufacturers/operators
data)
► Predictive (data analysis and periodic diagnostic
tests)
Reliability Centered Maintenance
► Process used to determine maintenance requirements
of any physical asset in its operating context.
► Plan is based upon reliability criteria with priority
given to the most critical components.
► Determine what types of failures are likely to occur.
► Focuses on preventing failures whose consequences
are likely to be serious.
► Emphasizes the use of predictive maintenance
practices.
► Utilizes previous aspects of reactive and preventive
maintenance concepts, in concert with root cause
analysis.
Strategy Development
► Advantages ► Disadvantages
 Towards more efficient  Can have significant startup
maintenance programmes. cost
 Eliminating unnecessary  Training
maintenance or overhauls.  Equipment
 Minimize frequency of  etc.
overhauls.  Savings potential not readily
 Reduced chance of sudden seen by management.
equipment failure.  Changes take time to
 Focuses maintenance implement
activities on critical
components.
 Increased component
reliability.
 Root causes of problems
identified.
Service Organizations
► Maintenance issues are not limited to manufacturing
► Transportation firms (airlines, railways, haulage,
dispatch companies, etc) must maintain vehicles in
good operating condition
► Highways Department must maintain roads
► Office personnel are reliant on computers, printers,
copiers and fax machines working properly
► As services become increasingly automated, service
firms face more and more maintenance issues
Computerised Maintenance
Management Systems
What is a CMMS?
► Computerized Maintenance Management System
► Very important operational and management tool
► Management of assets, improving reliability, reducing
downtime.
► CMMS functions:
 automating administrative tasks
 gathering relevant information
 develop and manage a maintenance strategy
 plan schedules for maintenance, replacements, upgrades.
Why use a CMMS?
► The primary purpose of a CMMS is to manage, capture, and track
inspection, maintenance and repair activities of an organization.
► Basic CMMS functionality
 providing work orders to cover repairs and maintenance of buildings, plant
and equipment.
 They provide a scheduling facility for maintenance for planned preventive
work on maintainable assets.
 And they also generally collect costing details for the labor and materials
related to the work performed.
► Advanced CMMS functionality
 analyse maintenance and repair processes
 visualise trends
 eliminate manual data entry
 incorporate alerts, triggers, and escalation procedures
 shift focus from administrative tasks to maintenance activities.
 assist in planning and predicting future needs, prolong asset life, manage
processes.
Requirement for CMMS
► Regularly scheduled equipment inspection and maintenance
prevents sudden and unexpected equipment failure and reduces
overall costs
► The management of these programs, in particular reporting
their current status and future needs, requires a CMMS.
Managing the operation of on-site maintenance staff and
contractors is a daunting and difficult task, however, if there is a
corresponding record within the CMMS then this tracking and
management is much easier.
► Even if you are duplicating data to what is in your contractor’s
CMMS (the contractor’s CMMS may not be on your premises), it
is extremely important that you have your own copy of data.
Your contractor may cease to exist and for the sake of future
reference and reporting it is essential you have your own CMMS
populated with your own data.
CMMS Information
► Consideration what information is stored – what do we WANT to keep,
and what do we HAVE to keep?
► manufacturer’s specifications
► management requirements
► , there are many statutory requirements and regulations that impact on
this question such as fire, health and safety, and environmental
legislation.

► Statutory requirements (programs) could be entered into a CMMS as a

scheduled maintenance plan with labor, materials and costs for
projecting estimated future costs. By keeping a corresponding record
in the CMMS and using the job number as a cross reference to the
paper record, the organization is able to quickly report on the status of
the statutory work in preparation to annual signoffs and/or audits.
► Those of you who have had work place safety audits are aware that
the first question asked is ‘Where are the maintenance records?’ A
maintenance plan that includes estimated costs can be compared with
the actual costs to ensure the effectiveness in the cost of asset
preservation.
Selection of a CMMS
► There are hundred of CMMS software packages on the market.
► A major problem is to select the most suitable package for the organisation.
 Look within your own organization and determine what is happening with the maintenance and
inspection functions. Check if there is an existing maintenance program in place, check its functions
and who manages the information gathering process.
 Determine what maintenance is required to be performed on the assets.
 Prepare some sort of brief as to the facility’s minimum and optimum requirements for a CMMS, the
resources to manage the database and time frame for implementation.
 Research between 3 and 5 providers. Have them present their product to assess the package in
terms of ease of use, functionality and ability to meet your requirements.
 Evaluate each proposal for specific CMMS functionalities:
 Does it address your specific requirements?
 Does it minimize unnecessary or duplicate data entry?
 Can you automate administrative tasks, reminders and notifications of upcoming events?
 Can you incorporate inspections, and other activities in your CMMS?
 Can you manage and track inventories?
 Web accessible?
 PDA version
 What is its ROI?
► This is a simplistic approach to the selection process, however, it will give most managers a
good starting guide to the selection of a CMMS.
Benefits of using CMMS
► Guarantee that all required tasks and activities are completed on time.
► Incorporate various mechanisms to ensure execution of tasks, including automatic listing of
activities, reminders, alerts, escalation procedures, and easy access to information.
► Improve reporting and analysis capabilities.
► Comply with Health and Safety Regulations.
► Improve Business Planning and make informed decisions.
► Improve operational efficiencies.
► Increase productivity and profitability.
► Perform activities effectively; simplify repeatable tasks; provide your staff with easy to use
tools that focus on performing tasks.
► Let your staff spend more time performing service activities and less time on paperwork
and data entry.
► Improve strategic and business planning; Analyze records, needs and patterns.
► Identify trends and highlight potential problem areas.
► Improve controls and accountability; Lead to better quality of work.
► Ensure that service is performed according to warranties, guidelines and regulations.
► Receive customized reports delivered to your email.
► There are many additional benefits of using a system using handheld devices, in
comparison with manual or paper-based processes: minimizing errors, increasing
accountability, and having the ability to quickly turn data into useful information. Last,
solutions must be cost effective and providers must be able to demonstrate their business
case and ROI (Return-On-Investment).
Need for a CMMS
► Requirements depend upon the size of the organization, type of
assets, number and quality of staff available.
► Should data be kept on computer - can it all be done on paper?
► Often preparation of reports for management is difficult and
time consuming because the raw data is not readily available
► Well-designed and easy-to-use CMMS solution can improve daily
activities as well as index and sort through years of information
related to the maintenance, cleaning and strategic planning of
buildings, plant and equipment.
► Regardless of the size of an organization a database of the work
performed must be maintained.
► Automation includes improvement of daily activities, automatic
tracking of inventories, better work assignments, and shift of
your focus towards exceptions, not routine matters.
Further Work
► Read the article
 Shibi, E. (2005) Common-Sense CMMS: Combining
Software and Handhelds. Maintenance
Technology, Vol. 18, No. 1, pp 47-49.
 www.cmmscity.com/articles/common_sense_cmms.htm