Maintenance Strategy &

Preventive Maintenance
Content

• Equipment maintenance strategy

• Five steps of making maintenance strategy.

• Practice
The emphasis of maintenance is to improve the
reliability and cost
MTBF
(Mean Time Between Failure)

Reliability MTTR
(Mean Time To Repair)

Availability

Maintenance
Spare parts cost

Cost Labor cost

Failure cost
Five basic criteria to evaluate equipment
maintenance effect
MTBF ▪ Interval time of specific parts or equipment’s failures occur
(Mean Time (actual or expected time)
Between Failure) ▪ This includes the time from 1 qualified product output to
st

equipment fault occurrence.

MTTR ▪ The time of maintain machine or equipment to certain condition

(Mean Time to (actual or expected time)
Repair) ▪ This include each stage of failures maintenance

▪ The percentage of available operation time.

Availability

▪ The possibility of a product or machine continuous

Reliability running in a particular time

Effective ▪ Percentage of effective maintaining time in the

Maintenance maintenance operation
workload

Data source：Nahmias; Steven; Product and repair analysis

The availability of equipment depends on
MTBF and MTTR

Calculate equipment's availability based on MTBF and MTTR that observed

in a particular time.

Operation total time Repair total time

MTBF = MTTR =
failure times+1 Repair times
(operation times)

MTBF
Availability =
MTBF+MTTR

Data source：Nahmias; Steven; Production and operation analysis

E.g. How to calculate MTBF, MTTR & availability

Operation situation

Operation time Operation time Operation time Operation time Operation time
4.5months 7months 2months 2months 3 months

Maintenance time Maintenance time Maintenance timeMaintenance time

3 days 1.5day 1day 2.5day

Term Definition Example

MTBF Mean time between failures (4.5 + 7 + 2 + 2 + 3) / 5 = 3.7 months

The average operation time of equipment
before fault occurrence
Mean time to repair (3 + 1.5 + 1 + 2.5 )/ 4= 2 days
MTTR
The average time that spend on maintenance
The percentage of equipment 111 / (111 +2 )= 98%
Availability operation time accounts for running
and maintenance time
Four choices of maintenance strategy
Yes
No

4. CBM

2. TBM 3. UBM Condition Based Maintenance

1. BDM Time Based Maintenance Usage Based Maintenance ▪ Check component regularly
▪ Check the availability of
Break Down Maintenance ▪ Replace or repair ▪ Replace or repair component
component after period of component after a certain ▪ Need understand the
▪ Replace or repair time (No matter machine hours information of many
component after failure actual situation ▪ Need understand the components.
occur using time of machine ▪ The components whether
▪ Understand and use the need be replaced or
component that used repaired basing on acquired
for failure repair information.
▪ Quick response for
repair

▪ Replacement and repair must be planned in advance

▪ Components must be ordered in advance and delivered on time

Reactive Preventive Predictive

▪ [Link]
How to choose maintenance strategy for
different equipment
High

The composition elements Unreliable equipment

of main equipment that that have high risk and
have quite long life direct impact on output,
expectancy, for example, Dangerous* High risk* for example, boiler, ball
steam turbine, generator mill, water pump.

Failures impact to value:

▪ Opportunity cost
(affordances/quality)）
▪ Environment/Safety Supporting equipment
▪ Maintenance cost Low risk** Unreliable** that have high
probability of failures, for
example, V-belt of
motor/pump
Be used for supporting
equipment, the failures of Low Low High
this kinds of equipment
won’t impact production Probability of failures
directly, for example, ▪ Supplier information
cooling fan, coffee maker. ▪ Equipment history
▪ Maintainer or operator’s
experience

* CBM，UBM，TBM
** If deviation from standard, need adjust, replace, repair or maintain failure
Source：M360
Practice 1

• Two examples of each:

1. BDM (Break Down Maintenance)
2. TBM (Time Based Maintenance)
3. UBM (Usage Based Maintenance)
Content

• Equipment maintenance strategy

• Five steps of making maintenance strategy

• Practice
There are five steps of making maintenance
strategy
1 2 3 4 5
Functional Making
Steps Equipment Critical
Component FMEA Maintenance
Breakdown Assessment
Breakdown Strategy
Working ▪ Breakdown ▪ Evaluate the ▪ Divide ▪ Hold a seminar, ▪ Make critical
Content equipment by critical functionality into confirm failure fixture
function and list components component level mode and effects maintenance
functional component of key projects strategy

▪ Make a structural ▪ Evaluate all plant ▪ According to the ▪ Determine the ▪ Divided into CBM,TBM,
Working tree; equipment from criticality possible root cause UBM and BDM1
Mode
▪ Divide equipment four aspects classification, priority of equipment failure ▪ Establish a database of
from functional – Production analysis functional ▪ Deeply clarify risk equipment
component level loss rate component. according to severity, ▪ Upload task to
▪ Establish all – Security ▪ Divide functional incidence and equipment
functional – Environment module into detectability management system
components list – Repair time component level (the ▪ Provide data base ▪ EMS repeatedly
▪ Regularly review minimum unit to be for strategy making generates maintenance
fixture criticality maintained tasks

▪ Equipment ▪ Equipment engineer /▪ Equipment engineer ▪ Equipment engineer ▪ Equipment engineer /

Working engineer / Technician / Technician Technician
person / Technician
Technician ▪ Maintainer ▪ Maintainer ▪ Maintainer
▪ Maintainer ▪ Production manager ▪ OP
▪ OP and OP
1 Planning maintenance includes condition based maintenance (CBM), time based maintenance (CBM), usage based maintenance (UBM) and
breakdown maintenance (BDM)
The first step：Equipment breakdown
1 2 3 4 5
Functional Making
Equipment Critical
Steps Component FMEA Maintenance
Breakdown Assessment
Breakdown Strategy
▪ Breakdown ▪ Evaluate the ▪ Divide functionality ▪ Hold a seminar, ▪ Make critical fixture
Working equipment by criticality of fixture into component confirm failure maintenance strategy
Content function and list functional level mode and effects
functional components of key projects
component
▪ Evaluate all plant ▪ According to the
Working ▪ Make a structural tree;
▪ Determine the ▪ Divided into CBM,TBM,
equipment from four possible root cause UBM and BDM1
Mode ▪ Divide equipment criticality classification,
from functional
aspects of equipment failure
priority analysis ▪ Establish a database
component level
– Product loss functional component. ▪ Deeply clarify risk of equipment
rate ▪ Divide functional according to severity,▪ Upload task to
▪ Establish all – Security module into incidence and equipment
functional – Environment detectability
component level (the management system
minimum unit to be ▪
components list – Repair time Provide data base ▪ EMS repeatedly
▪ Regularly review maintained for strategy making generates
fixture criticality maintenance tasks

Working ▪ Equipment engineer / ▪ Equipment engineer / ▪ Equipment engineer ▪ Equipment engineer ▪ Equipment engineer /
person Technician Technician / Technician / Technician Technician
▪ Maintainer ▪ Maintainer ▪ Maintainer ▪ Maintainer
▪ OP ▪ Production manager ▪ OP
and OP

1 Planning maintenance includes condition based maintenance (CBM), time based maintenance (CBM), usage based maintenance (UBM) and
breakdown maintenance (BDM)
Help to deeply understand specified equipment
Take chip mounter for example
Equipment Functional module Maintainable item

… …

Mounting head Holder

Compressor Nozzle

Vacuum pump Camera

Transmission
Shaft
rail

Master box …
CM chip mounter

Control box …
▪ Check if has this analysis in vendor side
… … ▪ Maybe need do deep-analysis manually
on critical items
… …

… …

… …

Data source：M360
The second step：
critical assessment of functional component
1 2 3 4 5
Functional Making
Equipment Critical
Steps Component FMEA Maintenance
Breakdown Assessment
Breakdown Strategy
▪ Breakdown ▪ Evaluate the ▪ Divide ▪ Hold a seminar, ▪ Make critical fixture
Working equipment by criticality of fixture functionality into confirm failure maintenance
Content function and list functional component level mode and effects strategy
functional components of key projects
component

Working
▪ Make a structural ▪ Evaluate all plant ▪ According to the ▪ Determine the ▪ Divided into CBM,TBM,
tree; equipment from four criticality classification, possible root cause UBM and BDM1
Mode
▪ Divide equipment aspects priority analysis of equipment failure ▪ Establish a database
from functional – Product loss rate functional component. ▪ Deeply clarify risk of equipment
component level – Security ▪ Divide functional according to severity,▪ Upload task to
▪ Establish all – Environment module into incidence and equipment
functional – Repair time component level (the detectability management system
components list ▪ Regularly review minimum unit to be ▪ Provide data base ▪ EMS repeatedly
fixture criticality maintained for strategy making generates
maintenance tasks

Working ▪ Equipment engineer ▪ Equipment engineer ▪ Equipment ▪ Equipment engineer ▪ Equipment engineer
person / Technician / Technician engineer / / Technician / Technician
▪ Maintainer ▪ Maintainer Technician ▪ Maintainer
▪ OP ▪ Production manager ▪ Maintainer
and OP ▪ OP

1 Planning maintenance includes condition based maintenance (CBM), time based maintenance (CBM), usage based maintenance (UBM) and
breakdown maintenance (BDM)
Applied in functional module
– CM chip mounter
FMEA’s
focal point. Partial Multiple Whole
Slow area area equipment
No loss down shutdown shutdown shutdown
Usually
Functional module 1 11 7 4 2 1 1 time/per week or
more.
1 Vacuum pump
2 Often
2 Holder 2 20 13 8 6 3 Between 1 time/ per week
Probability

3 Nozzle 3 and 1 time/ 6 weeks

4 Compressor Sometimes
3 20 17 14 8 9 5 Between 1 time/ 6 weeks
5 Master box and 1 time/ 6 months
6 Control box 1 Seldom
7 5 Between 1 time/ 6 months
4 23 21 18 15 10
7 Transmission rail 4 and 1 time/ 3 years
8 Shaft Rarely
5 25 24 22 19 12 6 ≤1 time/3 years（Ex:
1time/9 years.）

E D C B A
▪ Use the data that
collected by device to
prepare workshop. Consequence
▪ Collect the problems.
Help to deeply understand specified equipment
Take chip mounter for example
Equipment Functional module Maintainable item

… …

Mounting head Holder

Compressor Nozzle

Vacuum pump Camera

Transmission
Shaft
rail

Master box …
CM chip mounter

Control box …
▪ Check if has this analysis in vendor side
… … ▪ Maybe need do deep-analysis manually
on critical items
… …

… …

… …

Data source：M360
 The third step：
functional component breakdown
1 2 3 4 5
Functional Making
Steps Equipment Critical
Component FMEA Maintenance
Breakdown Assessment
Breakdown Strategy
▪ Breakdown ▪ Evaluate the ▪ Divide functionality ▪ Hold a seminar, ▪ Make critical fixture
Working equipment by criticality of fixture into component confirm failure mode maintenance
Content function and list functional level and effects of key strategy
functional component components projects

▪ Make a structural tree;▪ Evaluate all plant ▪ According to the ▪ Determine the ▪ Divided into CBM,TBM,
Working
Mode ▪ Divide equipment equipment from four criticality classification, possible root cause UBM and BDM1
from functional aspects priority analysis of equipment failure ▪ Establish a database of
component level – Product loss functional component. ▪ Prioritize risk equipment
▪ Establish all rate ▪ Divide functional according to severity, ▪ Upload task to
functional – Security module into possibility and equipment management
components list – Environment component level (the detectability system
– Repair time minimum unit to be ▪ Provide data base for ▪ EMS repeatedly
▪ Regularly review maintained strategy making generates maintenance
fixture criticality tasks

Working ▪ Equipment engineer / ▪ Equipment engineer ▪ Equipment ▪ Equipment engineer / ▪ Equipment engineer /
person Technician / Technician engineer / Technician Technician
▪ Maintainer ▪ Maintainer Technician ▪ Maintainer
▪ OP ▪ Production manager ▪ Maintainer
and OP ▪ OP

1 Planning maintenance includes condition based maintenance (CBM), time based maintenance (CBM), usage based maintenance (UBM) and
breakdown maintenance (BDM)
Help to deeply understand specified equipment

Take chip mounter for example

Equipment Functional module Maintainable item

… … Filter element

Mounting head Holder Spring

Compressor Nozzle Clamp holder

Vacuum pump Shaft Holder

Transmission
Camera
rail

CM chip Master box … LED lighting

mounter
Control box … Prism

… … Filter

… …
Let’s discuss… Data cable

▪ Can the holder be expanded?

… …
▪ Can the camera be expanded?
… …

Data source：M360
The fourth step：FMEA
1 2 3 4 5
Critical Functional Making
Steps Equipment Making Repair
Assessment Component FMEA Maintenance
Strategy
Breakdown
Breakdown Strategy
▪ Breakdown ▪ Evaluate the ▪ Divide functionality ▪ Hold a seminar, ▪ Make critical fixture
Working equipment by criticality of fixture into component confirm failure maintenance
Content function and list functional level mode and effects strategy
functional components of key projects
component

▪ Make a structural ▪ Evaluate all plant ▪ According to the ▪ Determine the ▪ Divided into CBM,TBM,
Working tree; equipment from four criticality classification, possible root cause UBM and BDM1
Mode ▪ Divide equipment aspects priority analysis of equipment ▪ Establish a database of
from functional – Product loss rate functional component. failure equipment
component level – Security ▪ Divide functional ▪ Deeply clarify risk ▪ Upload task to
▪ Establish all – Environment module into according to equipment management
functional – Repair time component level (the severity, incidence system
components list ▪ Regularly review minimum unit to be and detectability ▪ EMS repeatedly
fixture criticality maintained ▪ Provide data base generates maintenance
for strategy making tasks

▪ Equipment engineer ▪ Equipment engineer ▪ Equipment engineer ▪ Equipment engineer ▪ Equipment engineer
Working / Technician / Technician / Technician / Technician
person ▪ Maintainer / Technician
▪ Maintainer ▪ Maintainer ▪ Maintainer
▪ OP ▪ Production manager ▪ OP
and OP

1 Planning maintenance includes condition based maintenance (CBM), time based maintenance (CBM), usage based maintenance (UBM) and
breakdown maintenance (BDM)
What is the FMEA (Failure Mode and Effects Analysis)

Severity

EQP maintainable Risk priority Action

Failure mode Possibility
component number Plan
Occurrence
frequency

Detectability

▪ Risk Priority Number（RPN）= S* P* D (in a range of 1-729)

▪ Severity、Possibility and Detectability are in a range of 1-9
Establish RPN evaluation rule before grading
Example

Severity Possibility Detectability

Level Description Level Description Level Description
Failures are detected by professional
Any equipment failure will cause safety, health and
instrument equipment or special
9 environment accident, also will cause enterprise illegal 9 >1time/1shift 9
inspection method when device is
accident; loss caused > 500,000RMB
shutdown

Equipment failure cause production stop < 3 days, or

8 8 ≤1time/shift 8
direct loss and indirect loss < 300,000RMB

Equipment failure cause production stop < 2 days, or Failures are detected by onsite
7 7 ≤1time/1shift 7
direct loss and indirect loss < 200,000RMB inspection when device is shutdown

Equipment failure cause production stop < 1day, or

6 6 ≤1time/1week 6
direct loss and indirect loss caused < 100,000RMB.

Failures are detected by professional

Equipment failure cause production stop < 8 hours, or
5 5 ≤1time/3months 5 instrument equipment when device is
direct loss and indirect loss caused < 80,000RMB
running in daily work
Equipment failure cause production stop < 4 hours, or
4 4 ≤1time/6months 4
direct and indirect loss caused < 40,000RMB.
Failures are detected by onsite
Equipment failure cause production stop<2hours, or
3 3 ≤1time/1year 3 inspection when device is running in
direct and indirect loss <20,000RMB
daily work
Equipment failure cause production stop<1 hour, or
2 2 ≤1time/2years 2
direct and indirect loss<10,000RMB
When failure is occurring, equipment or
Equipment failure won’t cause production stop and ≤1time/5years
1 1 1 detection device could predict or alarm
overload, or no finance impact
the failure.
Sort failure mode based on RPN’s score
Failure
Component mode RPN

一级系统 二级组件 失效模式 严重性 可能性 可检测度 RPN 真空电磁阀 贴片不良 45

本体 吸料不良 2 4 5 40 滤芯 吸着不良 42
滤芯 吸着不良 2 7 3 42 嘴尖 吸着不良 42
Holder
弹簧 吸着不良 2 2 3 12 本体 吸料不良 40
夹爪 吸着不良 2 1 7 14 滑块 无动作 36
嘴尖 吸着不良 2 7 3 42 连杆 贴片不良 36
Nozzle 反光板 识别不良 2 6 1 12 本体 贴片不良 30
本体 贴片不良 2 5 3 30 数据线 通信不良 30
LED灯光 识别不良 2 1 7 14 上轴承 吸着不良 28
棱镜 贴片不良 4 1 5 20 下轴承 吸着不良 28
Camera
滤光板 真空压低 3 1 7 21 O轴电机 贴片不良 24
数据线 通信不良 3 2 5 30 滤光板 真空压低 21
滑块 无动作 3 4 3 36
棱镜 贴片不良 20
连杆 贴片不良 3 4 3 36
Shaft Z轴电机 贴片不良 20
上轴承 吸着不良 4 1 7 28
MC16 Z轴卡 无动作 15
下轴承 吸着不良 4 1 7 28
MC15 O轴卡 无动作 15
真空管 真空压低 2 2 1 4
吹气电磁阀 贴片不良 15
真空气路 气压管 真空压低 2 2 1 4
夹爪 吸着不良 14
检测Sensor 无动作 2 3 1 6
X轴电机 无动作 4 1 3 12 LED灯光 识别不良 14
Y轴电机 无动作 4 1 3 12 弹簧 吸着不良 12
电机 反光板 识别不良 12
O轴电机 贴片不良 4 2 3 24
Z轴电机 贴片不良 4 5 1 20 X轴电机 无动作 12
数据线 数据线 无动作 6 2 1 12 Y轴电机 无动作 12
MC16 Z轴卡 无动作 5 3 1 15 数据线 无动作 12
功能板卡
MC15 O轴卡 无动作 5 3 1 15 检测Sensor 无动作 6
真空电磁阀 贴片不良 3 5 3 45 真空管 真空压低 4
电磁阀
吹气电磁阀 贴片不良 3 5 1 15 气压管 真空压低 4
Source：Team analysis
The fifth step：Making repair strategy
1 2 3 4 5
Functional Making
Steps
Equipment Critical
Component FMEA Maintenance
Breakdown Assessment
Breakdown Strategy
Working ▪ Breakdown ▪ Evaluate the ▪ Divide ▪ Hold a seminar, ▪ Make critical
equipment by criticality of fixture functionality into confirm failure fixture
Content
function and list functional component level mode and effects maintenance
functional components of key projects strategy
component
▪ Make a structural ▪ Evaluate all plant ▪ According to the ▪ Determine the ▪ Divided into CBM,
Working tree; equipment from criticality possible root cause TBM, UBM and BDM1
Mode ▪ Divide equipment four aspects classification, priority of equipment failure ▪ Establish a database
from functional – Product loss analysis functional ▪ Deeply clarify risk of equipment
component level rate component. according to ▪ Upload task to
▪ Establish all – Security ▪ Divide functional severity, incidence equipment
functional – Environment module into and detectability management system
components list – Repair time component level (the ▪ Provide data base ▪ EMS repeatedly
▪ Regularly review minimum unit to be for strategy making generates
fixture criticality maintained maintenance tasks

Working ▪ Equipment ▪ Equipment engineer / ▪ Equipment engineer ▪ Equipment ▪ Equipment engineer /

person engineer / Technician / Technician engineer / Technician
Technician ▪ Maintainer ▪ Maintainer Technician ▪ Maintainer
▪ Maintainer ▪ Production manager ▪ OP
▪ OP and OP

1 Planning maintenance includes condition based maintenance (CBM), time based maintenance (TBM), usage based maintenance (UBM)
and breakdown maintenance (BDM)
Making maintenance strategy by
general risk assessment and decision tree
Replace malfunction
N BDM
equipment
If CBM has N If TBM has
Y advantage on advantage on
overall cost? overall cost? Replace equipment
Y TBM/UBM based on predefined
time interval
Y ▪ Once degradation
CBM Replace equipment monitoring
based on actual mechanism and risk
If failure risk If system to be condition monitor
can be measured has are listed, a simple
Y Y decision tool can help
acceptable? cost
effectiveness? to define suitable
maintenance strategy.
N
▪ Frequency should be
If defined by specialist
degradation/risk Y Replace equipment based on their
N If TBM has TBM
monitoring can based on predefined experience, MTBF
be evaluated? cost
effectiveness? N time interval and equipment history,
and it also be
Redesign2 improved continuously

Y
N If random
failure? N TBM Replace equipment
based on predefined
time interval
[Link] all spare parts’ business impact
[Link] discuss with supplier
Source：M360
The fifth step：Making repair strategy

1 2 3 4 5

Functional Making
Equipment Critical Component FMEA Maintenance
Breakdown Assessment Breakdown Strategy

Breakdown Prioritize Breakdown Prioritize Make a

decision
Content

• Equipment maintenance strategy

• Five steps of making maintenance strategy

• Practice
Practice- riding electric bicycle to commute

27
Practice of electric bicycle
Machine Module Component

5
Answer
Machine Module Component

5
Thank you.