TATYASAHEB KORE INSTITUTE OF ENGINEERING AND
TECHNOLGY, WARANANAGAR
Approved by AICTE New Delhi and affiliated to Shivaji University,
Kolhapur
Twice Accredited by National Board of Accreditation New Delhi
NAAC Accredited “A” Grade Institute with CGPA 3.27
AN AUTONOMOUS INSTITUTE
INDUSTRIAL MAINTANANCE ENGINEERING
UNIT-2
Maintenance Models
Dr. M. R. Jadhav (Asst. Prof.)
Department of Mechanical Engineering,
TKIET
Minimal Repair
• "Minimal repair" typically refers to a maintenance strategy where
only the minimum necessary repairs are performed to restore
equipment or assets to a functional state. This approach aims to
minimize downtime and costs by addressing immediate issues
without undertaking extensive repairs or overhauls.
• Focus on Immediate Issues: Minimal repair focuses on
addressing immediate problems or failures that affect equipment
functionality or performance. It prioritizes the resolution of critical
issues to minimize downtime and disruptions to operations.
• Cost-Effective: The goal of minimal repair is to achieve
functionality at the lowest possible cost. This often involves
prioritizing low-cost repair options and avoiding unnecessary or
costly repairs that do not significantly impact equipment
performance.
Temporary Solutions: In some cases, minimal repair involves
implementing temporary or interim solutions to quickly restore
equipment functionality while more comprehensive repairs or
replacements are planned or scheduled.
Risk Management: While minimal repair can help reduce costs and
downtime in the short term, it may also entail risks associated with
deferred maintenance or incomplete repairs. Organizations must
carefully assess the risks and benefits of minimal repair strategies
and ensure that critical safety and reliability requirements are met.
Balancing Act: Minimal repair is a balancing act between
addressing immediate needs and ensuring the long-term reliability
and performance of equipment. Organizations must strike a balance
between minimizing costs and risks in the short term while
maintaining the integrity and longevity of assets over time.
Monitoring and Follow-Up: After implementing minimal repairs,
it's essential to monitor equipment performance closely and follow
up with any necessary further actions. This may include additional
repairs, preventive maintenance, or long-term planning for
equipment replacement or upgrades.
Documentation and Tracking: Proper documentation of minimal
repair activities is crucial for tracking maintenance history,
identifying recurring issues, and informing future maintenance
decisions. Organizations should maintain detailed records of repairs
performed, associated costs, and equipment performance metrics.
Overall, minimal repair strategies can be valuable tools for
addressing immediate maintenance needs and minimizing downtime
and costs. However, they should be implemented judiciously and as
part of a broader maintenance strategy that considers long-term
reliability, safety, and operational requirements.
Maintenance Types
Maintenance types can be broadly categorized into several
categories based on their objectives and methodologies.
Preventive Maintenance:
Objective: Prevent equipment failure and maintain equipment in
optimal condition.
Methodology: Scheduled inspections, lubrication, calibration,
cleaning, and replacement of worn parts to prevent breakdowns and
prolong equipment life.
Corrective Maintenance:
Objective: Repair equipment after it has failed or malfunctioned.
Methodology: Reactive response to equipment failures, aiming to
restore functionality as quickly as possible to minimize downtime.
Predictive Maintenance:
Objective: Anticipate and prevent equipment failures by monitoring
equipment condition and performance in real-time.
Methodology: Utilizes sensors, monitoring systems, and predictive
analytics to detect early signs of equipment degradation or failure,
allowing for timely maintenance interventions.
Reliability-Centered Maintenance (RCM):
Objective: Optimize maintenance strategies to maximize equipment
reliability and minimize costs.
Methodology: Analyze equipment functions, failure modes, and
consequences to develop customized maintenance plans that
prioritize critical assets and failure modes.
Condition-Based Maintenance (CBM):
Objective: Perform maintenance based on the condition of
equipment rather than fixed schedules.
Methodology: Monitors equipment condition using techniques such
as vibration analysis, thermography, oil analysis, and ultrasonic
testing to determine maintenance needs.
Total Productive Maintenance (TPM):
Objective: Improve overall equipment effectiveness (OEE) by involving
operators in maintenance activities and promoting a culture of
continuous improvement.
Methodology: Emphasizes proactive maintenance, autonomous
maintenance by operators, early equipment management, and focused
improvement activities.
Risk-Based Maintenance (RBM):
Objective: Prioritize maintenance activities based on risk assessment to
minimize the likelihood and consequences of equipment failures.
Methodology: Evaluates the probability and consequences of failure for
each asset, allocating maintenance resources according to the level of
risk.
Run-to-Failure Maintenance:
Objective: Only perform maintenance when equipment fails, minimizing
upfront maintenance costs but risking increased downtime and potential
safety hazards.
Methodology: Reactive response to failures without proactive
Preventive Maintenance Methodology
Preventive maintenance is a proactive approach to maintenance that
aims to prevent equipment failure before it occurs. There are
several methodologies commonly used in preventive maintenance:
Time-based maintenance: This involves scheduling maintenance
activities at regular intervals, such as weekly, monthly, quarterly, or
annually. For example, changing filters every three months or
lubricating machinery every week.
Usage-based maintenance: Maintenance is performed based on
the amount of usage or runtime of the equipment. This approach
involves tracking equipment usage and performing maintenance
after a certain number of operating hours, cycles, or miles.
Predictive maintenance: Predictive maintenance utilizes data from
sensors, monitoring systems, and historical performance data to
predict when maintenance is needed. Techniques such as vibration
analysis, thermography, oil analysis, and ultrasonic testing are used
to detect early signs of equipment failure.
Reliability-centered maintenance (RCM): RCM is a systematic
approach that identifies the most critical components of a system and
determines the most effective maintenance strategy for each
component. It involves analyzing the functions, failure modes, and
consequences of failure for each component to optimize
maintenance efforts.
Condition-based maintenance (CBM): CBM involves monitoring
the condition of equipment in real-time to determine when
maintenance is needed. This approach relies on sensors and
monitoring systems to detect abnormalities or changes in equipment
condition that may indicate the need for maintenance.
Total productive maintenance (TPM): TPM focuses on
maximizing the efficiency and productivity of equipment by
involving operators in routine maintenance tasks, promoting a
proactive approach to maintenance, and emphasizing the importance
of equipment reliability to overall business goals.
Risk-based maintenance (RBM): RBM prioritizes maintenance
activities based on the level of risk associated with equipment
failure. It involves assessing the likelihood and consequences of
failure for each piece of equipment and allocating maintenance
resources accordingly.
Failure-finding maintenance: This methodology involves
intentionally testing or inspecting equipment to find hidden failures
that may not be detected through routine maintenance activities. It is
often used for critical systems where the consequences of failure are
severe.
Different industries and organizations may use a combination of
these methodologies based on their specific needs, the criticality of
their equipment, and available resources.
The goal of preventive maintenance is to minimize unplanned
downtime, reduce repair costs, and maximize the reliability and
lifespan of equipment.
Balancing Preventing Maintenance (PM) and breakdown
maintenance
• Preventive maintenance and breakdown maintenance both seek to
maintain and repair equipment, but they have very different ways
of doing this
• Preventive maintenance identifies any issues before equipment
failure or downtime, through routinely scheduled maintenance.
Breakdown maintenance works by running equipment until it
breaks down, in which case repairs and maintenance are
performed.
• Preventive maintenance operates based on a schedule, where
maintenance tasks are completed at specific intervals prior to
downtime events. This is because the goal of preventive
maintenance is to maximize the lifespan and runtime of
equipment.
Breakdown maintenance is somewhat specific because it’s not
applicable to many pieces of equipment.
For example, it is not a suitable maintenance strategy for anything
involved in human safety and health, nor is it a good strategy for
critical or central pieces of equipment.
However, it works well with things that are designed to be used until
they’re inoperable. This can include everything from light bulbs to
residential water heaters. Even though a water heater may be
considered a critical piece of equipment, the time spent PMing a
water heater—which includes disrupting the resident every X
months—is probably more intrusive than fixing a broken system
every decade or so. This shows that breakdown maintenance is
applicable for critical pieces of equipment in certain cases,
especially in the property management space.
Preventive maintenance, on the other hand, is a solid maintenance
plan for almost all pieces of equipment in a factory setting. In a
residential setting, however, it only makes sense to perform PMs on
equipment in non-living areas.
• Preventive maintenance (PM) is • Breakdown maintenance (BM) is
work that is scheduled based on work that is only performed when a
calendar time, asset runtime, or piece of equipment breaks down or
some other period of time. has a downtime event.
• Maintenance software for • Maintenance software for downtime
scheduling. triggers
• Maintenance scheduler (for • Necessary replacement equipment
larger organizations). • Lowers overall costs of non-critical
• Extends the lifetime of assets. manufacturing equipment.
• Optimizes planning of • Minimizes preventive maintenance
maintenance and resources. costs on nonessential equipment
• Can be expensive to keep up • Can’t be used for many types of
over the long term. equipment, especially safety
• Labor intensive due to constant equipment
maintenance tasks • Requires careful planning and
execution to work effectively
Preventive maintenance schedules: deviations on both
sides of target values
When creating preventive maintenance schedules, it's important
to account for potential deviations on both sides of target values
to ensure flexibility and adaptability. Here's how you can
manage such deviations:
Define acceptable ranges: Establish acceptable ranges or
tolerances around target values for preventive maintenance
tasks. These ranges should take into account variations in
equipment performance, environmental factors, and other
relevant variables.
Monitor performance: Regularly monitor equipment
performance and condition to detect deviations from target
values. Use condition monitoring techniques, sensor data,
inspection reports, and historical maintenance records to
identify trends and patterns.
Adjust schedules: When deviations are detected, evaluate the
impact on maintenance schedules and adjust accordingly. If
equipment performance exceeds expectations, consider extending
maintenance intervals or deferring certain tasks. Conversely, if
performance deteriorates or deviations indicate potential issues,
expedite maintenance activities or increase frequency as needed.
Prioritize critical tasks: Focus on maintaining critical equipment
within target values to minimize the risk of unplanned downtime
and ensure operational reliability. Allocate resources and attention
based on the criticality of equipment and the consequences of
failure.
Implement risk-based approach: Assess the likelihood and
consequences of equipment failure to prioritize preventive
maintenance tasks. Allocate resources based on the level of risk
associated with deviations from target values, focusing efforts
where they are most needed to mitigate potential impacts.
Utilize condition-based monitoring: Implement condition-based
monitoring techniques to detect deviations in real-time and trigger
maintenance actions proactively. This allows for timely
intervention before deviations lead to equipment failures or
performance issues.
Document and analyze deviations: Document all deviations from
target values and analyze the root causes to identify opportunities
for improvement. Use this information to refine maintenance
strategies, optimize schedules, and enhance overall reliability.
Continuous improvement: Emphasize a culture of continuous
improvement by regularly reviewing and updating preventive
maintenance schedules based on feedback, lessons learned, and
evolving operational requirements. Encourage collaboration
between maintenance, operations, and engineering teams to drive
ongoing optimization efforts.
Preventive maintenance schedules: functional
characteristics
Functional characteristics of preventive maintenance schedules
refer to the key attributes or components that define how preventive
maintenance activities are planned, executed, and managed. These
characteristics ensure that preventive maintenance schedules are
effective, efficient, and aligned with organizational goals. Here are
some functional characteristics:
Frequency: Determine the frequency at which preventive
maintenance tasks are performed. This could be based on time
intervals (e.g., daily, weekly, monthly) or usage metrics (e.g.,
operating hours, cycles).
Task list: Define a comprehensive list of preventive maintenance
tasks required for each piece of equipment. This includes
inspections, lubrication, calibration, cleaning, and other activities
necessary to maintain equipment reliability.
Priority: Establish priorities for preventive maintenance tasks
based on equipment criticality, safety considerations, regulatory
requirements, and operational needs. Ensure that resources are
allocated appropriately to address the most critical maintenance
activities first.
Resource allocation: Allocate resources such as labor, materials,
tools, and equipment to execute preventive maintenance tasks
efficiently. Consider factors such as skill levels, availability, and
workload when assigning personnel to specific tasks.
Scheduling: Develop a structured schedule for performing
preventive maintenance tasks, taking into account equipment
availability, production schedules, and other operational
constraints. Balance the need for regular maintenance with the need
to minimize disruption to production processes.
.
Documentation: Maintain accurate records of preventive
maintenance activities, including task completion dates, findings,
observations, and any corrective actions taken. Documentation
helps track equipment history, monitor performance trends, and
comply with regulatory requirements
Notification and reminders: Implement systems to notify
maintenance personnel when preventive maintenance tasks are due
or overdue. Use reminders, alerts, and notifications to ensure timely
execution of maintenance activities and minimize the risk of missed
tasks.
Performance monitoring: Monitor equipment performance and
condition to assess the effectiveness of preventive maintenance
efforts. Utilize condition monitoring techniques, sensor data, and
performance metrics to identify trends, detect anomalies, and
optimize maintenance strategies.
Adaptability: Maintain flexibility to adjust preventive
maintenance schedules based on changing operational conditions,
equipment performance, and organizational priorities.
Continuously evaluate and refine maintenance schedules to
optimize resource utilization and maximize equipment reliability.
Continuous improvement: Foster a culture of continuous
improvement by regularly reviewing preventive maintenance
practices, soliciting feedback from maintenance personnel, and
implementing lessons learned. Identify opportunities to streamline
processes, enhance efficiency, and improve overall maintenance
effectiveness.
By incorporating these functional characteristics into preventive
maintenance schedules, organizations can optimize equipment
reliability, minimize downtime, and maximize operational
performance.
Replacement models
Replacement models are mathematical tools used in operations
management and decision-making to determine the optimal time to
replace equipment, machinery, or assets.
These models help businesses balance the costs associated with
maintaining existing equipment against the costs of replacing it.
Here are two common types of replacement models:
Economic Replacement Models:
a. Equivalent Annual Cost (EAC): The EAC model calculates
the annual cost of owning and operating an asset over its useful
life, taking into account initial purchase costs, maintenance
expenses, salvage value, and any other relevant costs. By
comparing the EAC of keeping the existing asset with the EAC of
replacing it with a new one, decision-makers can determine the
most cost-effective option.
b. Minimum Cost Replacement Model: This model aims to minimize
the total cost of ownership by identifying the optimal replacement time.
It considers factors such as the initial cost of the asset, maintenance
costs, salvage value, and the cost of downtime or lost productivity
associated with equipment failure. The objective is to replace the asset
at the time that minimizes the total cost over its useful life.
Age Replacement Models:
a. Time-Based Replacement Model: In this model, equipment is
replaced at fixed intervals or after a certain number of years, regardless
of its condition. The decision to replace is based solely on the age of the
asset and does not consider its current performance or condition.
b. Failure-Based Replacement Model: This model involves replacing
equipment when its probability of failure exceeds a certain threshold or
when it no longer meets performance requirements. Maintenance data,
reliability analysis, and predictive modeling techniques are used to
estimate the probability of failure and determine the optimal
replacement time.
Key considerations when using replacement models include:
Cost Analysis: Thoroughly analyze all relevant costs associated
with both maintaining existing equipment and replacing it with
new equipment.
Risk Management: Assess the risks associated with equipment
failure, downtime, and potential disruptions to operations.
Technological Advances: Consider technological advancements
that may improve the efficiency, productivity, and capabilities of
new equipment compared to existing assets.
Lifespan and Depreciation: Account for the expected lifespan of
equipment and its depreciation over time when calculating costs
and determining replacement intervals.
Sensitivity Analysis: Conduct sensitivity analysis to assess the
impact of changes in key variables (such as maintenance costs,
asset lifespan, and discount rates) on the optimal replacement
decision.
