Maintenance Strategies

Dr David Baglee
School of Computing and Technology
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 activities
implement
on critical components.
 Increased component
reliability.
 Root causes of problems
identified.
Costs
Total
Cost

Predictive
Direct Cost

Preventive

Reactive

Indirect Cost
Trade-off between Repairs and PM

Minimum Total
Maintenance Cost
Total
Annual Cost

Maintenance
Costs
Preventive
Maintenance
Cost
Breakdown
and Repair
Cost
Degree of Preventive Maintenance
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
Trends in Maintenance
► Production machinery is becoming more and
more complex and maintenance personnel
must keep pace
► Special training programs to maintain worker
skill level
► Subcontracting service companies
► Production workers maintain own equipment
► Computer assistance in maintenance