Proceedings of the International MultiConference of Engineers and Computer Scientists 2012 Vol II,

IMECS 2012, March 14 - 16, 2012, Hong Kong

Maintenance Planning Based on Computer-Aided

Preventive Maintenance Policy
Islam H. Afefy
Abstract-In the present work, maintenance planning based on
computer-aided preventive maintenance policy are introduced.
The focus of this paper is on preventive maintenance activities.
Preventive maintenance involves the repair, replacement, and
maintenance of equipment in order to avoid unexpected failure
during use. The aim of this study is to build the preventive
maintenance program and is to improve system availability and
maintenance resources. The preventive maintenance program
results indicate that the availability and reliability have
increased for three specifications M/C under investigation. For
first Longitudinal Seaming machine, the result shows that the
machine availability increases from 75.6 % to 90.34 %. While,
machine reliability improves around 3.97 % for the proposed
preventive maintenance. In case of second Longitudinal
Seaming machine, as global results, about 14.4% and 4.31% of
the machine availability and reliability are increased for the
proposed preventive maintenance, respectively. In addition, the
Rotary machine availability improves from 86.287 to 92.21 %
and the machine reliability improves from 3.95% for the
proposed preventive maintenance. Moreover, obtained results
showed that using such preventive maintenance program will
eliminate the six big losses; time losses, setup and adjustment
losses, idling and minor stoppages losses, lowering machine
operational speed losses, scrap & rework losses and production
start up losses.
Index TermsReliability.

Preventive

Maintenance,

Availability,

I. INTRODUCTION
reventive maintenance (PM) is a schedule of planned
Maintenance actions aimed at the prevention of
breakdowns and failures. The primary goal of preventive
maintenance is to prevent the failure of equipment before it
actually occurs. It is designed to preserve and enhance
equipment reliability by replacing worn components before
they actually fail. Preventive maintenance activities include
equipment checks, partial or complete overhauls at specified
periods, oil changes, lubrication and so on. Optimal
maintenance strategies for systems with partial repair options
and without assuming bounded costs are introduced by Peter
Bruns [1].
The PM is an important policy of a maintenance
planning. Within a maintenance organization, it usually
accounts for a major proportion of the total maintenance
effort. There are seven elements of the PM as shown in Fig.1
[2]. Optimal maintenance scheduling of power producers
considering unexpected unit failure is proposed to minimize
the risk associated with unit unexpected failure [3].
Scheduled maintenance or maintenance performed based

I. H. Afefy is with the Industrial Engineering Department - Faculty of

Engineering- Fayoum University-Egypt (e-mail: [email protected],
[email protected])

ISBN: 978-988-19251-9-0
ISSN: 2078-0958 (Print); ISSN: 2078-0966 (Online)

on the condition of an item conducted to ensure safety,

reduce the likelihood of operational failures, and obtain as
much useful life as possible from an item. The PM consists
of actions intended to prolong the operational life of the
equipment and keep the product safe to operate. This manual
defines two types of the PM: Scheduled and Condition-based.
In both cases, the objectives of the PM are to ensure safety,
reduce the likelihood of operational failures, and obtain as
much useful life as possible from an item [4], [5].

Servicing

Testing

Inspection

Alignment

Adjustment
Elements
of PM
Calibration

Installation

Fig. 1. Elements of the PM.

Also, the PM will result in savings due to an increase of

effective system service life. Long-term benefits of the PM
include:
Decreased system downtime (MDT).
Decrease failure rate ().
Improved system reliability (R).
Improved system availability (A).
Decreased cost of replacement.
Better spare parts inventory management.
Improve maintenance resources.
Yang [6] studied a condition-based preventive maintenance
arrangement for thermal power plants". Also, a hybrid Petri
net modeling method coupled with fault-tree analysis (FTA)
are used. The PM, reliability centered maintenance (RCM)
and total productive maintenance (TPM) to maintenance
problems all aim at enhancing the effectiveness of machines
to improve the maintenance productivity(see Ashayeri [7] ).
A model for preventive maintenance planning by genetic
algorithms based in cost and reliability (see Lapa et al [8]).
Badia and Berrade [9] have discussed the optimal
maintenance policy of a periodically inspected system under
imperfect repair. Sayed et al [10] studied computer aided
reliability for optimum maintenance planning. The
optimized preventive maintenance plan was obtained
IMECS 2012

Proceedings of the International MultiConference of Engineers and Computer Scientists 2012 Vol II,
IMECS 2012, March 14 - 16, 2012, Hong Kong

through the computer program at minimum cost by

determining maintenance intervals. The PM policy
optimization for multipurpose plant equipment is introduced
by Dedopoulos and Shah [11]. Amir et al, [12] used fuzzy
rules as an artificial intelligence (AI) tool used to determine
priority of activities.
In this paper, a computer-aided preventive maintenance
planning (CAPMP) will proposed. Mathematical model will
used to calculate maintenance labor force, maintenance
downtime, maintenance resource, reliability and availability
within this context. In the final section, applicability of the
PM policy is examined on the practical case for three
specifications M/C.
II. PREVENTIVE MAINTENANCE ANALYSIS
Preventive maintenance will generally run the equipment
more efficiently resulting in maintenance cost savings. While
we will not prevent equipment catastrophic failures, we will
decrease the number of failures. Minimizing failures
translate into maintenance. Preventive maintenance is a
schedule of planned maintenance actions aimed at the
prevention of breakdowns and failures, since the primary
objective of preventive maintenance is to prevent the failure
of equipment before it actually occurs. Preventive
maintenance parameters are:
1. Maintenance labor force.
2. Maintenance downtime.
3. Maintenance spare parts.
4. Total maintenance cost.
5. Maintenance Tasks.
6. Maintenance W/O.
A. Modelling of the PM labor force.
In the model, a specific formula is present to define the
size of preventive maintenance labor force (LPM) as:
LPM = mdannual / LOC
(1)
Where, mdannual is the total preventive maintenance annual
man-day, and LOC is the workers operating conditions
(day/year).
The total preventive maintenance annual man-day can be
calculated as:
mdannual= f annual * Tdu * Lnumber
(2)
Where, f annual is the annual frequency per preventive
maintenance type, Tdu is the duration time, and Lnumber is the
number of workers per preventive maintenance type.
B. Modelling of availability (A)
Availability is a measure of the degree to which an item is
in an operable state and can be committed at the start of a
mission when the mission is called for at an unknown point
in time [13]. The relationship between the concepts of
availability from mean time between failure (MTBF), mean
downtime (MDT), Mean response time (MST)) and mean
time to maintenance (MTTM) are presented in Fig. 2. The
machines are reliable when their MTBF are higher. As
contrast, the lower is better for MDT.
Nf * (MTBF)
A=
(3)
Nf * (MTBF+ MDT)

ISBN: 978-988-19251-9-0
ISSN: 2078-0958 (Print); ISSN: 2078-0966 (Online)

MDT=MST+MTTM

(4)

AT - Nf * MDT

MTBF =
Failure Rate ()=

(5)

Nf
Nf

(6)
AT - Nf * MDT
Where, Nf is the number of failure and AT is the available
time.
Available time for production
(AT)

MDT

MTBF

MST

MTTM

Down
UP

UP

Fig. 2. The relationship between A, MTBF, MDT, MST and MTTM.

C. Modelling of reliability
Reliability is the probability of survival under a given
operating environment. For example, the time between
consecutive failures of a refrigerator where continuous
working is required is a measure of its reliability [13], [14].
R (t) = exp (-t/MTBF) = exp (-t)
(7)
Where, is the constant failure rate and MTBF is the mean
time between failures. MTBF measures the time between
system failures and is easier to understand than a probability
number. For exponentially distributed failure modes, MTBF
is a basic figure-of-merit for reliability (failure rate, , is the
reciprocal of MTBF).
D. Modelling of the total maintenance cost
Maintenance cost (Cm) can be calculated by the follow
equation:
Cm= CSp + DT*Cv
(8)
Where, CSp is the spare parts cost, DT is the down time, and
Cv is the variable cost per hour of down time, its include
labor rate and crew size.
The production losses cost (Cp) is estimated using the
following formula:
Cp= DT* PLos *SPrice
(9)
Where, PLos is the production loss in unit per hour, and
SPrice is the unit selling price of the product.
III. PM SOFTWARE OVERVIEW
The goal of the software program was to establish general
machines preventive maintenance program that would
machine minimize downtime (DT) and improvement
machine availability. It is a multi-plate form (visual basic

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Proceedings of the International MultiConference of Engineers and Computer Scientists 2012 Vol II,
IMECS 2012, March 14 - 16, 2012, Hong Kong

language) oriented object program, compatible with

windows.
As in Fig. 3, maintenance program data flow from the input
phase and output phase are introduced. The PM for the
building program after the data collected from the plant, now
the time to build a program according to this data by
extracting it and making analysis for it.

Inputs
- Machine
code
- - -Failures
--MTTR
- -Downtimes
- -Maintenance
resources

Tools
- Mathematical
Modeling.
- PM
program

Outputs
- PM labor
size
- PM schedule
- Maintenance
cost
- Availability
- Reliability

Fig. 4. Main page and maintenance (W/O) of the PM program.

System reliability and availability forms are introduced in

Fig. 5. The Figure shows availability and reliability forms for
the system and it has the ability of adding, removing and
saving for any data related to system.

Fig. 3. Maintenance data flow from the input phase to the output phase.

The main page (see Fig. 4) of the program is considered

the main engine to move to all parts of program because it
has the buttons that go to the all forms of program, also
button to quit the program and button to show form of
program designer.
A. Software functions
Conceptually, the functions to be performed are as
following:1. Maintenance labor size force.
2. Spare parts cost.
3. Availability.
4. Reliability.
5. Maintenance resource analysis.
6. The maintenance work order (W/O).
7. Total maintenance cost.
As in Fig. 4, the W/O form is presented. The figure
shows the maintenance W/O forms of the plant and by it is
available to add, delete and save of the W/O number by the
main task bar.
Fig. 5. System reliability and availability forms of the PM program.

V. CASE STUDY
The present research has been applied for Automotive
Exhaust Systems of the Abu El -Yazeed Group, Egypt. The
main product for company is the Exhaust systems. The main
components of the muffler are introduced in Figure 6. The
design capacity of the Muffler assembly is about 400 per
hour. The different stages to form the muffler and our study
will be on the linear seaming machine in muffler assembly
shop are presented in Fig. 7.
A. Problem statement
In Egyptian manufacturer of Automotive Exhaust
Systems, the current policy in this company is the corrective
maintenance policy (CM). The production loss
(muffler/hour) of the process is caused mainly by the
stoppage of the company production line. Thus, the
ISBN: 978-988-19251-9-0
ISSN: 2078-0958 (Print); ISSN: 2078-0966 (Online)

IMECS 2012

Proceedings of the International MultiConference of Engineers and Computer Scientists 2012 Vol II,
IMECS 2012, March 14 - 16, 2012, Hong Kong

production loss costs are usually concentrated on the random

breakdown events for Longitudinal Seaming and Rotary
machines. So, the application of (CAPMP) is applied to
obtain the optimum preventive maintenance interval.
B
C

B. Data collection
The data collections of the item for the Longitudinal
Seaming machines have been collected. The data have been
collated from the following sources:- Maintenance records.
- Operation logbooks.
- Labor working with or maintaining.
C. Results
The PM schedules and maintenance tasks for machines
are presented in Table I. This table shows yearly, six monthly
and three monthly maintenance tasks.

TABLE I
PM schedules for machines.

Fig. 6. Muffler components.

Yearly
maintenance
tasks
Replacement of
oil seal.
Replacement of
orifice.
Change oil trunk.

Fig. 7. The Longitudinal Seaming machine.

Production Line
Raw material stock (Sheets & Pipes)

Sheet metal cutting

(cylindrical)

Piping cutting

Shear of chamfer
Assembly the internal
assemble

Logo print

Six monthly
maintenance
tasks

Three monthly
maintenance
tasks

Replacement of
coupling

Filter cleaning

Motor bearing
greasing.
Pump vibration
analysis (900RH).

Cleaning the
electrical circuit
by dry air.

Bearing
replacement.
Change the
hydraulic oil
Motor vibration
Current analysis
after 5000 work
analysis.
hour.
Appling the sixAppling the
monthly
Oil analysis.
weekly
maintenance.
maintenance.
In Table II, main downtime and current availability for
Longitudinal seaming and rotating machines are presented.
Also, main downtime and proposed availability for
Longitudinal Seaming and Rotating machines are shown in
Table III.

Assembly of muffler body

TABLE II
Results of availability (AC) analysis for Longitudinal Seaming and Rotating
machines for the corrective maintenance (current policy).

Assembly of muffler body

Item

Lateral seaming

Assembly of body with piping and Hungers

1
2
3

Machine
Name
Longitudinal
Seaming
machine1
Longitudinal
Seaming
machine 2
Rotary machine

Machine
Nf
MDT
Code
(Failure (Day)
/year)
208201
16
3.975

AC
(%)

208202

16

4.25

74.24

M05B

17

2.115

86.287

75.6

Longitudinal seaming

Painting

Final production
storage
Fig. 8. Company production line.

ISBN: 978-988-19251-9-0
ISSN: 2078-0958 (Print); ISSN: 2078-0966 (Online)

As in Fig. 9, the availability analysis for Longitudinal

Seaming and Rotating machines is introduced. This figure
shows that Longitudinal Seaming machine1 availability
increases from 75.6 % to 90.34 %. Also, it is found that
Longitudinal Seaming machine 2 availability increases from
74.24% to 88.64% for the proposed preventive maintenance.
On other hand, the rotary machine availability improves
from 86.287% to 92.21% for the proposed preventive
maintenance.
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Proceedings of the International MultiConference of Engineers and Computer Scientists 2012 Vol II,
IMECS 2012, March 14 - 16, 2012, Hong Kong
TABLE III
Results of availability (Ap) analysis for Longitudinal Seaming and Rotating
machines for the preventive maintenance (proposed PM).

Item
1
2
3

Machine
Name

Machine
Code

Longitudinal
Seaming
machine1
Longitudinal
Seaming
machine 2
Rotary
machine

Nf
MDT
(Failure (Day)
/year)

208201
208202
M05B

TABLE V
Results of reliability analysis for Longitudinal Seaming and Rotating machines
for the preventive maintenance (proposed PM).

AP
%

Item

2.845

90.34

3.75

88.64

2.573

92.21

Machine
Nf
Average
P R(t)
Code (Failure MTBF (Failure %
/year) (day)
/day)
Longitudinal 208201
Seaming
9
26.5 0.03775 96.3
machine1
Longitudinal 208202
Seaming
8
29.25 0.0349 96.57
machine 2
Rotary
M05B
8
30.43 0.03287 96.77
machine
Machine
Name

Fig.
Fig. 9. The availability analysis for longitudinal seaming and rotary
machines.

10.

In Table IV, the MTBF and failure rate for Longitudinal

seaming and rotating machines for current policy are listed.
Also, main downtime and proposed reliability for
Longitudinal Seaming and Rotating machines are presented
in Table V.
As in Fig. 10, the reliability analysis for Longitudinal
Seaming and Rotating machines is presented. It is found that
first Longitudinal Seaming machine reliability increases
from 92.33% to 96.3 % for the proposed PM and it is found
that second Longitudinal Seaming machine reliability
increases from 92.26% to 96.57 % for the proposed PM and
Rotating machine reliability improves from 92.82% to
96.77%.

Fig. 10. The reliability analysis for the Longitudinal seaming and Rotary
machines.

The annual downtime cost for machines is introduced in Fig.

11. The results show that the annual downtime cost for first
Longitudinal Seaming machine decreases from 305*10 6LE
to 123*106LE for proposed the PM. On the other hand, the
annual downtime cost for second Longitudinal Seaming
machine decreases 326*106LE as compared to 144*106LE
for proposed the PM. Moreover, about 42.8 % of the annual
downtime cost for rotary machine is saved when proposed
the PM other corrective maintenance once

TABLE IV
Results of reliability analysis for Longitudinal Seaming and Rotating machines
for the corrective maintenance (current policy).

Item Machine
Name
1
2
3

Longitudinal
Seaming
machine1
Longitudinal
Seaming
machine 2
Rotary
machine

Machine
Nf
Average
R(t)
C
Code (Failure MTBF (Failure %
/year) (day)
/day)
208201

16

12.525 0.07984 92.33

208202

16

12.25

0.08163 92.26

M05B

17

13.4

0.07455 92.82

ISBN: 978-988-19251-9-0
ISSN: 2078-0958 (Print); ISSN: 2078-0966 (Online)

Fig. 11 . Annual downtime cost for Longitudinal Seaming and Rotary

machines

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Proceedings of the International MultiConference of Engineers and Computer Scientists 2012 Vol II,
IMECS 2012, March 14 - 16, 2012, Hong Kong

VI. CONCLUSION
This paper described a preventive maintenance program
tool which was designed to calculate the size of maintenance
labor force, spare parts cost, total maintenance cost, number
of work order, reliability, and availability). By applying the
proposed preventive maintenance program, it is possible to
find preventive maintenance policies which provide a high
level of availability and reliability for all machines (Figures 9
and 10). The improvement in availability and reliability for
indicates the explicit benefit of the PM policy.
ACKNOWLEDGMENT
The author wishes to express his thanks to the
maintenance management of the Abu El -Yazeed Group
Egypt, for their support during carrying out this work.
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ISBN: 978-988-19251-9-0
ISSN: 2078-0958 (Print); ISSN: 2078-0966 (Online)

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