Sustainable Project Maintenance
[Link]. In Construction Management
III Semester
Lecturer: Er. Suman Bhattarai
B.E. In Civil Engineering
[Link]. In Construction Management
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Chapter - Two
Types of Maintenance
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Contents:
• Preventive maintenance
• Predictive maintenance
• Condition-based maintenance
• Reliability-Centered maintenance (RCM)
• Total productive maintenance
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❑ Maintenance:
• Maintenance is work that is carried out to preserve an asset, in order to
enable its continued use and function, above a minimum acceptable
level of performance, over its design service life, without unforeseen
renewal or major repair activities.
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❖ Reasons for maintenance:
• Maintenance serves to protect the owners’ real estate investment in a number
of ways.
✓Physical Integrity: To keep the assets in good working order so as to minimize
disruptions and downtimes.
✓Risk Management: To keep the assets in a state of good repair for the owners’
health and safety.
✓Aesthetic Preservation: To keep the assets from deteriorating in appearance and
becoming unsightly.
✓Responsible Stewardship: To ensure that the assets achieve their full potential
service life.
✓Duty of Care: To satisfy a legislated duty that is owed to owners, occupants and
guest on the property.
✓Duty to Mitigate: To prevent unnecessary damage to assets that may result in
their premature failure.
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❑ Preventive Maintenance:
• Preventive maintenance is a proactive approach to maintenance that
involves conducting regular maintenance activities, such as cleaning,
lubrication, and inspection.
• It is used for equipment that requires regular maintenance and has
predictable failure patterns.
• It is said that preventive maintenance is a stich in time that saves time.
• “Prevention is better than cure.”
• Preventive maintenance refers to maintenance action performed to
keep or retain a machine/equipment or asset in a satisfactory operating
condition.
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• Preventive maintenance helps in stopping unexpected breakdowns
through timely maintenance and saves money over expensive
emergency repairs and replacements.
• Increase safety
• Less expenses on repair
• Assets operated consistently with preventive maintenance have
extended lifecycles.
• Preventing operational disruptions enables organizations to sustain
higher efficiency and output.
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❖ Example of preventive maintenance:
• Air filters play a critical role in maintaining indoor air quality and
system performance in HVAC systems. However, over time, these
filters can become clogged with dust, debris, and other contaminants,
which can restrict air flow, reduce efficiency, and increase energy
consumption.
• This ultimately costs more money in repairs, replacements, and the
costs from unplanned breakdowns.
• Regularly cleaning or replacing the air filters keeps the system running
smoothly and avoids these issues. It’s a simple and effective way to
prevent problems before they even start and help extend the lifecycles
of HVAC systems.
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❖ Way to run effective preventive maintenance
programs:
• Develop a maintenance schedule to ensure maintenance tasks are
performed on time and consistently.
• Create an inspection checklist that outlines the tasks to be performed
during each maintenance check to ensure consistency and
completeness.
• Maintain maintenance records for all maintenance activities, including
the date of service, the technician who performed the task, and any
replacement parts used.
• Keep a close eye on inventory to ensure the availability of the
necessary lubricants, oils, fluids, and replacement parts for equipment.
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❑ Predictive Maintenance:
• Predictive maintenance relies on the collection of data from various sensors
installed on the equipment, such as vibration sensors, temperature sensors,
and acoustic sensors, among others.
• The data collected is then analyzed using machine learning algorithms,
which use historical data to identify patterns and detect anomalies that
indicate a fault is likely to occur.
• Predictive maintenance allows early detection of equipment issues through
continuous monitoring, allowing problems to be addressed before failure
occurs. This increases uptime and reliability.
• Predictive maintenance provides for ono-stop monitoring and predicting
future risks, which enables smarter prioritization of repairs and more
focused spending. This optimizes costs.
• Predictive maintenance avoids unnecessary work and expenses from overly
maintenance schedules. Spending is targeted based on projected operational
risk.
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❖ Examples of predictive maintenance:
• Consider a large grocer that relies on refrigeration units to keep
products fresh and safe for customers. But what happens when one of
these units breaks down??
➢Not only does it impact the quality of food products, but can also
result in lost sales and a negative customer experience.
➢By installing temperature sensors in refrigeration units and using
machine learning algorithms to analyze the data, it can be predicted
when a unit is likely to fail before it actually does.
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❖ Benefits of predictive maintenance:
• Facilitates condition-based maintenance (CBM) to optimize maintenance
schedules based on the actual operating conditions of the equipment.
• Supports the use of machine learning (ML) and artificial intelligence (AI)
algorithms to analyze data in real-time and predict equipment failure with
greater accuracy.
• Provides insights into the root causes of equipment failures, which can help
inform design improvements and reduce the likelihood of similar failures in
the future.
• Facilitates remote monitoring and control of equipment, reducing the need
for on-site maintenance and enabling centralized management of assets
across multiple locations.
• Improves supply chain management by ensuring that critical equipment and
components are available when needed, reducing the risk of delays and
disruptions. 12
❑ Condition-Based Maintenance:
• Condition-based maintenance, also known as CBM, is an advanced
maintenance strategy that relies on real-time data to determine when
maintenance should be performed.
• CBM uses a variety of technologies, such as sensors and monitoring
equipment, to measure and track the condition of equipment in real
time.
• This way, maintenance is performed only when necessary, reducing
downtime and unnecessary maintenance costs.
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❖ Example of how condition-based maintenance
works:
• Consider an industrial plant that uses large pumps to move fluids
through a network of pipes. These pumps are critical to the plant’s
operation, and any unexpected downtime can result in costly
production losses.
• With CBM, the plant can continuously monitor the health of the
pumps by collecting data on parameters such as temperature,
vibration, and flow rate.
• This data is analyzed in real-time by machine learning algorithms to
detect any abnormal patterns that they may indicate a potential failure.
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• Condition-based maintenance is commonly applied to a wide range of
equipment, such as electric motors, pumps, compressors, turbines,
HVAC systems, bearings, gearboxes, diesel engines, etc.
❖Benefits of CBM:
➢Increased equipment availability and reduced downtime.
➢Extended equipment lifespan and improved reliability.
➢Reduced maintenance costs through targeted and efficient
maintenance.
➢Enhanced environmental sustainability through reduced waste and
energy consumption.
➢Improved data collection and analysis for better decision making.
➢CBM provides a more accurate assessment of equipment condition,
allowing for more informed decision-making regarding repair,
replacement, or upgrades and enabling you to make significant
performance improvements without the need for massive and upfront
capital investments. 15
❑ Reliability-Centered Maintenance (RCM):
• Reliability-Centered Maintenance (RCM) is a corporate-level
maintenance strategy that is implemented to optimize the maintenance
program of a company or facility.
• The final result of an RCM program is the implementation of a
specific maintenance strategy on each of the facility’s assets.
• The maintenance strategies are optimized so that the productivity of
the plant is maintained using cost-effective maintenance techniques.
• Teams implementing RCM use maintenance planning, asset condition
monitoring, predictive maintenance, and preventive maintenance to
avoid costly equipment failure.
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❖ Where is reliability-centered maintenance used?
• Reliability-centered maintenance began in aviation industry where
it still remains a prominent practice, and has become popular in
other industries like:
✓Military equipment manufacturing
✓Nuclear power
✓Steel manufacturing
✓Aviation
✓Sanitation for food distribution
✓Pharmaceutical manufacturing.
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• RCM is always used where there are high consequences for failure.
• For example; a defect in a pharmaceutical drug can affect several
thousands of people taking it potentially causing harm, illness, or even
death. This is why pharmaceutical manufacturers implement an RCM
strategy.
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• There are four principles that are critical for a reliability-centered
maintenance program:
✓The primary objective is to preserve system function.
✓Identify failure modes that can affect the system function.
✓Prioritize failure modes.
✓Select applicable and effective tasks to control the failure modes.
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❖ Advantages & Disadvantages of RCM:
✓Advantages:
• Implementing RCM increases equipment availability and reduces
maintenance and resource costs.
• Maintenance cost, injury risk, and potential failure are factors in the
implementation of RCM for a facility.
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✓Disadvantages:
• RCM does not consider the total cost of owning and maintaining an
asset.
• Additional costs of ownership, like those considered in evidence-based
maintenance, are not taken into account, and are therefore not factored
into the maintenance considerations.
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❖ The RCM process: Seven steps to implement
reliability centered maintenance:
✓Selection of equipment for RCM analysis.
✓Define the boundaries and function of the systems that contain the
selected equipment.
✓Define the ways in which the system can fail (failure modes).
✓Identify the root causes of the failure modes.
✓Assess the effects of failure.
✓Select a maintenance tactic for each failure mode.
✓Implement and then regularly review the maintenance tactic selected.
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❑ Total Productive Maintenance (TPM):
• Total Productive Maintenance (TPM) is the process of maximizing
equipment effectiveness through the active involvement of all
supporting departments.
• The goal of TPM is to improve overall productivity by optimizing
equipment availability.
• The main objective of TPM is to create a system that enhances
workers’ abilities to maintain and keep up with the well-being of
facility assets.
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❖ By implementing TPM processes, we can:
• Manage multi-location, day-to-day maintenance life cycles.
• Optimize asset utilization.
• Gain insights into real-time performance data.
• Employ an ecosystem approach.
• Bridge the gaps between maintenance, reliability, and operations.
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❖ The six different areas of loss improved by TPM
include:
• Unexpected breakdowns.
• Set-up and adjustment.
• Stoppage.
• Speed.
• Quality.
• Equipment and capital investment.
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• Total Productive Maintenance is a set of extra measures that further
tune current processes to attempt to bring a facility as close as possible
to “perfect production.”
• TPM frames maintenance as a business advantage- reducing
downtime, waste, and equipment failure and increasing production and
profit.
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❑ Green Maintenance:
• Green maintenance refers to the adoption of environmentally friendly
practices in the maintenance and operation of industrial equipment and
facilities.
• It encompasses a range of activities aimed at reducing waste,
conserving energy, and minimizing the environmental impact of
maintenance processes.
• The goal is to create a sustainable maintenance strategy that not only
enhances operational efficiency but also aligns with the broader
environmental goals of the organization.
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❖ Key principles of Green Maintenance:
• Reduce, Reuse, Recycle: This principle emphasizes minimizing waste
by reducing consumption, repurposing materials whenever possible,
and recycling resources to prevent them from ending up in landfills.
• Energy Efficiency: Involves optimizing the energy consumption of
maintenance activities, adopting energy-efficient technologies, and
implementing smart systems that minimize energy waste. By focusing
on energy efficiency, green maintenance not only reduces operational
costs but also mitigates the environmental impact associated with
excessive energy consumption.
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• Eco-friendly materials and products: Green maintenance prioritizes
the use of eco-friendly materials and products throughout its
processes. This includes choosing sustainable and responsibly sourced
materials, as well as utilizing cleaning agents, lubricants, and
maintenance products that have minimal impact on the environment.
• Biodiversity conservation: This principle emphasizes creating and
maintain landscapes that support local ecosystems, fostering habitat
diversity, and promoting the well-being of flora and fauna.
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❖ Benefits of implementing Green Maintenance
practices:
• Reduced environmental impact
• Cost savings
• Improved reputation
• Regulatory compliance
• Improved health and well-being
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❖ Challenges and solutions:
✓Common obstacles in adopting Green Maintenance practices:
• Initial cost concerns.
• Lack of awareness.
• Resistance to change.
• Limited availability of green products.
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✓ Strategies to overcome resistance and barriers:
• Demonstrating return on investment (ROI).
• Education and training programs.
• Engaging leadership.
• Collaboration and networking.
✓Government incentives and certification programs:
• Tax incentives
• Grants and rebate programs
• Certification programs
• Green building certifications.
• Regulatory compliance.
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THE END
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