Chapter 2 :
Maintenance Strategies
A maintenance strategy defines the rules for the
sequence of planned maintenance work in the Plant
Maintenance (PM) application component.
It contains general scheduling information, and can
therefore be assigned to as many maintenance task
lists (PM task lists) and maintenance plans as
required.
.
Maintenance Function
Inspect.
To determine the serviceability of appropriate technical
publications, an item by comparing its physical and
mechanical.
Repair.
The application of maintenance function at the indicated
category services (inspect, test, service, adjust, align, of
maintenance).
Replace.
The act of substituting a service the appropriate sub column lowest
level of able like type part, subassembly, or module maintenance
authorized to perform the function.
Install.
The act of emplacing, seating, or maintenance functions, it is
solely for purpose of fixing into position an item, part, module
having the group numbers and (component or assembly)
Adjust.
To maintain, within prescribed components. limits, by bringing
into proper or exact position, or by setting the operating
characteristics to the specified parameters.
Service.
Operations required periodically to build is the highest degree of
material maintenance applied to Army equipment. The rebuild to
clean (decontaminate), to preserve, to drain, operation includes
the act returning to zero to paint, or to replenish fuel, lubricants,
hydraulic fluids, or compressed air supplies.
Align.
To adjust specified variable elements group numbers, the purpose
of which is to of an item to bring about optimum or desired identify
components, assemblies, subassemblies, and modules with the next
higher performance.
Basic of selecting maintenance
function
Selecting and appropriate maintenance strategy and choosing one
or more techniques becomes a simpler decision when the failure
modes are understood.
A schematic of the decision process in selecting an appropriate
maintenance strategy.
a. Prepare for the Analysis
b. Select the Equipment to Be Analyzed
c. Identify Functions
d. Identify Functional Failures
e. Identify and Evaluate (Categorize) the Effects
of Failure
f. Identify the Causes of Failure
g. Select Maintenance Tasks
System Approach to Maintenance
Function
a. Identification of the needs of maintenance related activities,
which may include repair, reconditioning or replacement of
components.
b. Analyzing the requirement of the above needs.
c. Determining the functional procedures for maintenance task
selection. Work planning and scheduling, work order
processing, etc.
d. Outlining a reporting and controlling procedure of all
maintenance related activities.
e. Development of supporting services and infrastructure for
efficient execution of maintenance functions.
f. Determining the cost account procedures for optimizing
maintenance related expenditures.
g. Adopting a policy for training of maintenance staff and
assurance of quality.
Types Of Maintenance
And Its Applications
Breakdown Maintenance
Repairs or replacement performed after a machine
has failed to return to its functional state following
a malfunction or shutdown
Usually assigned to machines with backups in place,
or machines which are of low importance to
production.
Corrective Maintenance
Maintenance which is required after an item has
failed or worn out, to bring it back to the working
order.
Detect, isolate and rectify a fault so that the failed
equipment or machine can be restored to its normal
operable state.
Examples of a corrective maintenance :
Replacement of a failed electrical breaker
Weld repair of a cracked process line
Repair of a failed instrument transmitter
Preventive Maintenance
Maintenance performed while a machine is still in
working order to keep it from breaking down.
Lubricating, tightening and replacing worn parts.
Advantages
Less standby equipment is needed
Cost of repairing is reduced
Lowers wear and tear of a machine and other
equipment
Increases the life of the machine
Provide greater safety and protection to the
workers
Reliability Based Corrective
Maintenance
Maintenance which replaces these no value task
with specific maintenance that prevents failures
and prolong the useful life of plant assets.
Advantages :
Increase in cost effectiveness, machine uptime, and a
greater understanding of the level of risk that the
organization is managing.
PREDICTIVE MAINTENANCE
( PDM)
DEFINITION
Activities that detects changes in the physical condition
of equipment in order to carry out the appropriate
maintenance.
Classified into 2 : condition based predictive
maintenance & statistical based predictive maintenance
ADVANTAGE
Increased equipment lifetime.
Increased plant safety.
Fewer accidents with negative impact on environment.
Optimized spare parts handling.
APPLICATION
Create templates, PM records (or PMs) :used to generate
scheduled preventive maintenance work orders.
Provide detailed descriptions of (PM) work by assigning
job plans to PMs.
Specify a (PM) schedule for an asset or location.
Select specific days, months, or seasons to generate work
orders from a PM.
Create a PM hierarchy to schedule a group of work
orders for an asset or location hierarchy.
RELIABILITY CENTERED
MAINTENANCE (RCM)
DEFINITION
Process to ensure that assets continue to do what their
users require in their present operating context.
Generally : used to achieve improvements in fields such
as the establishment of safe minimum levels of
maintenance, changes to operating procedures and
strategies and the establishment of capital maintenance
regimes and plans.
PROCESS OF (RCM)
Select asset based on critically.
Define boundaries.
Select & train the facilities team.
Perform audit of recommendation.
Priotize & implement recommendation.
Measure result.
Update RCM document to include changes.
ADVANTAGE
Greater safety & environment integrity.
Enhanced understanding of equipment.
Increased availability & reliability.
Greater maintenance efficiency.
Longer equipment life.
Better teamwork.
Complete maintenance strategy.
TOTAL PREVENTIVE MAINTENANCE
(TPM)
DEFINITION
"Periodic and systematic inspections and detections of
plant/machinery, targeting at identifying deterioration
- panned restoration of detected deterioration"
Other names : SCHEDULED MAINTENANCE --
PERIODIC MAINTENANCE -- PLANNED
MAINTENANCE -- ROUTINE MAINTENANCE.
PURPOSE OF (TPM)
Preventive Maintenance
Autonomous Maintenance
Maintainability Improvement
Maintenance Prevention
2.2.3 Identify maintenance concept
use or apply in industry
a. Initially implemented in high-to-medium volume
production areas.
b. Successfully applied in:
low-volume production
high-to-low volume assembly
Development areas
Warehouse
Whole range of industry
Condition-based Maintenance
System (CBM)
METHODOLOGY
condition-based maintenance (CBM), shortly
described, is maintenance when need arises. This
maintenance is performed after one or more indicators show
that equipment is going to fail or that equipment
performance is deteriorating.
CBM. A maintenance technique closely related to PDM that
involves monitoring machine condition and predicting
machine failure. Many CBM systems are controlled by
computers.
METHODOLOGY (CONT…)
This concept is applicable to mission critical systems that
incorporate active redundancy and fault reporting. It is also
applicable to non-mission critical systems that lack
redundancy and fault reporting.
CBM is based on using real-time data to prioritize and
optimize maintenance resources. Observing the state of the
system is known as condition monitoring
METHODOLOGY (CONT…)
The system will determine the equipment's health, and act
only when maintenance is actually necessary.
Ideally condition-based maintenance will allow the
maintenance personnel to do only the right things,
minimizing spare parts cost, system downtime and time
spent on maintenance.
RISK BASED MAINTENANCE
RBM???
Opportunities for incremental improvement by eliminating
low-value tasks and introducing tasks that address high
commercial risk areas. Risk-based maintenance evaluates
the current commercial risk and analyzes the costs and
benefits of steps to mitigate failures.
PURPOSE RBM
To develop and manage inspection and maintenance plans
for new and existing assets (including offshore and
onshore plants, structures, pipelines).
RBM CONCEPT
Managing risk = Find the right balance
Asset risk concepts fimiliar to most :
probability of event X consequence of event
Most approaches only look at technical site
Risk Associated With
Implementation
Time – availability, time management
Organisation – right skills, right responsibilities
Energy- short term and long term to drive success
The End …..
Thank you …………