MAINTENANCE MANAGEMENT

Maintenance Strategies
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CHAPTER 2
MAINTENANCE STRATEGIES

2.1 Introduction to Maintenance Strategies

✓ Definition of maintenance strategies:

Rules for the sequence of planned maintenance work in the Plant Maintenance
(PM) application component.
Action plans for achieving a desired future state for the maintenance functions.
Covering all aspects of maintenance management which sets the direction for
maintenance management.

✓ Basic of selecting maintenance strategies:

Prepare for the analysis e.g: seal damage problem
cause the leak of oil.
Select the equipment to be analyzed e.g: replace the new seal.
Identify functions e.g: to stop the leaking oil.
Identify functional failures e.g: to reduce damage on
piston pump.
Identify and evaluate the effect of failures e.g: serviceable conditions.
Identify the cause of failures e.g: tear and wear seal.
Select maintenance tasks e.g: corrective maintenance.

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Maintenance Strategies
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2.2 Concepts of Maintenance Function

✓ Selecting an appropriate maintenance function is necessary to make the condition of

components in higher performance.

✓ Several systems that approach maintenance function:

Condition Monitoring (CM) System:
process of recording measurements in different machine parameters that
conveys the condition of machine without disrupting operation.
e.g: oil analysis, process variable analysis, thermal imaging.
Reliability Centered Maintenance (RCM) System.
process of defines system boundaries and identifies system function,
functional failures and failure modes in specific operating context.
steps select asset based on critical conditions.
define boundaries.
select and train the facilities team.
perform audit of recommendation.
implement the recommendation.
measure the results.
update RCM documentation to include changes.
advantages greater safety and environment integrity.
enhanced understanding of equipment.
increased availability and reliability.
greater maintenance efficiency.
longer equipment life.
better teamwork.
complete maintenance strategy.

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Maintenance Strategies
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Condition Based Maintenance (CBM) System.
performed after one or more indicators show that equipment is going to fail
or equipment performance is deteriorating.
using real time data to prioritize and optimize maintenance resources.
advantages minimize spare parts cost.
minimize system downtime.
minimize the time spent on maintenance.
Failure Modes and Effects Analysis (FMEA) System.
process of identifying the function on an asset, the ways it can fail to perform
intended functions, the cause of the failures and the methods of detecting
those failures.
Failure Modes, Effects and Criticality Analysis (FMECA) System.
integral part of RCM directed to determine type, probability, cause and
consequences of potential failures.
Root Cause Failure Analysis (RCFA) System.
process of identifying the fundamental cause that prevents recurrence of
adverse condition.
Computerized Maintenance Management System (CMMS) System.
used to measure, manage and analyze maintenance process including task
planning and scheduling, inventory control and management, labor and
material cost accounting and asset historical data.
Taxonomy.
technique of classification and cataloguing of items.

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Maintenance Strategies
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✓ Lists of maintenance functions:
Inspect to determine the appropriate technical serviceability.
Test to verify serviceability and operating condition.
Service to keep an item in proper operating condition.
Adjust to set the operating characteristic to the specified parameters.
Align to adjust specified variable elements to higher performance.
Calibrate to detect and adjust any discrepancy.
Install to emplace any function needed.
Replace to substitute a service.
Repair to indicate category service.
Overhaul to restore serviceable equipment into best operational
condition.
Rebuild to restore unserviceable equipment.

✓ TEN ways to consider appropriate maintenance function:

Improve equipment efficiency and reduce scrap rate.
Maximize production or increase facilities availability at the lowest cost.
Highest quality and safety standard.
Minimize energy usage.
Reduce breakdowns and emergency shutdowns.
Optimize the useful life of equipment.
Optimize resource utilization.
Provide reliable cost and budgetary control.
Reduce downtime.
Identify and implement cost reduction.
Improve spare stocks control.

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✓ SEVEN decision processes after selecting appropriate maintenance function:
Prepare for the analysis.
Select the equipment to be analyzed.
Identify functions.
Identify functional failures.
Identify and evaluate the effect of failures.
Identify the causes of failures.
Select maintenance task.
Provide reliable cost and budgetary control.

2.3 Classification of Maintenance

Figure 2.1: Classification of Maintenance

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✓ TWO categories in maintenance classification planned maintenance.
unplanned maintenance or known
as run to failure maintenance.

✓ Advantages of planned maintenance:

Less is needed in standby equipment.
Reducing the cost of repairs.
Reducing wear and tear of machines and other equipment.
Increase the life of the machines.
Enhanced understanding of equipment.
Providing greater safety and protection to the workers.
Optimize spare parts handling.
Increasing the greater of maintenance efficiency.
Making better teamwork.

✓ Disadvantages of unplanned maintenance:

Expensive in terms of both direct and indirect cost.
The occurrence of failure in a component can cause failures in other
components which lead to low production availability.
Difficult to schedule in advance.

✓ Predictive maintenance:
Activities that detect changes in physical condition of equipment in order
to carry out the appropriate maintenance.
Classified into TWO condition based maintenance.
statistical based maintenance.

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✓ Preventive maintenance:
Maintenance is performed before the occurrence of a failure in order to protect
and to prevent any degradation during operating conditions.
Activities include inspection, analysis, cleaning, lubricating, tightening,
replacing and overhaul.
Several kinds of preventive maintenance:
routine repetitive and periodic activities.
e.g: cleaning and lubricating.
running carried out while the machine is running.
opportunity carried out when unplanned opportunity exists.
window carried out when machines are not required for a period.
shut down carried out when the production line is in total stop.
Advantages or benefits increased component operational life.
allows for corrective action.
reduced process downtime.
reduced cost for parts and labor.
reduced capital costs.
reduced maintenance costs.
reduced code violations.
reduced cost of business interruption.

✓ 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 a machine with back up in place or machines which are
low importance to production.

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✓ Improvement maintenance as known as reliability centered maintenance:
Process to ensure that assets continue to do what their users require in
present operating context.
Generally used to achieve improvements in fields such as the establishment
of safe minimum levels of maintenance, change to operating procedures
and strategies and the establishment of capital maintenance regimes and
plans.
THREE types:
design out redesign the machines and facilities which are
vulnerable to frequent occurrence of failure.
engineering services construction, modification, removal, installation
and rearrange facilities.
shut down performed when the production line is in total
stop.

✓ Corrective maintenance:
Maintenance which is required after an item has failed or worn out in order
to bring it back to work properly.
Detect, isolate and rectify a fault so that the failed equipment or machines
can be restored to its normal operable state.
Activities include adjusting, aligning, calibrating, reworking, removing and
replacing.
THREE types:
remedial performed to eliminate the source of failure without
interrupting the continuity of the production process.
deferred not immediately initiated after the occurrence of failure.
shut down performed when the production line is in total stop.
FOUR steps to perform fault detection.
fault isolation.
fault elimination.
verification of fault elimination.

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2.4 Introduction to Total Productive Maintenance (TPM)

✓ Maintenance improvement strategy involving all staff members in the organization to

optimize equipment reliability and ensure efficient management of plant assets.

✓ A holistic approach to equipment maintenance strives to achieve perfect production

that are zero interruptions, zero defects and zero accidents.

✓ Methodology originated by Japan to support lean manufacturing system.

✓ Objectives to increase production while at the same time increasing employee

morale and job satisfaction.
to operate in a manner.
to avoid wastage in the changing economic environment.
to produce goods without reducing product quality.
to reduce manufacturing costs.
to avoid defective products.
to maintain accident free environment.

✓ Basic element methods autonomous maintenance.

focused maintenance.
planned maintenance.
quality maintenance.
education and training.
safety, health and environment.
office TPM.
development management.

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ELEMENT METHODS

Figure 2.2: Basic Element Methods of TPM

✓ Tools to analyze and solve problems Pareto Analysis.

Statistical Process Control.
Brainstorming.
Cause Effect Diagram.
Team Based Problem Solving.
Poka Yoke System.
5S.
Benchmarking.
Bottleneck Analysis.
Reliability, Maintainability and Availability
(RMA) Analysis.
Simulation System.

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Evolution towards
TPM

Breakdown
Maintenance

Preventive
Maintenance

Predictive
Maintenance

Corrective
Maintenance

Reliability Centered
Maintenance

Condition Based
Maintenance

Computerized
Maintenance
Management System

Total Productive
Maintenance

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Maintenance Strategies
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✓ Factors for successful implementation top management contributions.
cultural transformations.
employee involvement.
traditional and proactive maintenance
policies.
training and education.
maintenance prevention.
maintenance excellence.
basic equipment care.
equipment improvement.
knowledge and skills.

✓ Barries in implementation cultural resistance to change.

partial implementation of TPM.
lack of training and education.
lack of organizational communication.
overly optimistic expectations.

✓ SEVEN steps initial cleaning of machines, equipment and surroundings.

countermeasures at the source of problems.
cleaning and lubricating standards.
general inspection.
autonomous inspection.
organization and tidiness.
full autonomous maintenance.

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