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Introd uction to Maintenance

Dr. Munthear Alqaderi


munthear@gmail.com
Question?

• Why do we need maintenance?


• What are the costs of doing maintenance?
What are the costs of not doing
maintenance ?
What are the benefits of maintenance?
How can maintenance increase profitability
of company?
Inspection & Test Procedures
Imagine
II .... ...

I I .. ... ..

I I .. ... ..

I I .. ... ..

II .......

• Imagine having no maintenance system


Maintenance in Service Industry

• Hospital
• Transport companies
• Banks
• Gas station
• Shopping malls I retail
• Restaurants
• Hotels and resorts
Maintenance in Manufacturing Companies

• Refinery
• Petrochemicals
• Electronic
• Automotive
• Furniture
• Ceramics
• Food and beverages
• Operators less able to do repairs
themselves
• Machine and product failure can have
effect on company's operation and
profitability
• Losses due to breakdown
• Maintenance and reliability is important
• Maintenance and product quality
• Maintenance and productivity
• Maintenance and safety
• Maintenance and supply chain
• Failure cause disruption, waste,
accident, inconvenience and expensive
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NFM11:111J. t t l f)
Failure
• Failure - inability to produce work in
appropriate manner
• Equipment I machine failure on production
floor - worn out bearing, pump, pressure
leaks, broken shaft , overheated machine etc.
• Equipment failure in office - failure of power
supply, air-conditioned system , computer
network , photocopy machine
• Vehicle failure - brake, transmission , engine,
cooling system
Maintenance History

1. In the period of pre-World War II, people


thought of maintenance as an added cost to the
plant which did not increase the value of
finished product.
------- - --------
Therefore, the maintenance at that era was
restricted to fixing the unit when it breaks because
it was the cheapest alternative
Maintenance History

2. During and after World War II at the time when the


advances of engineering and scientific technology
developed, people developed other types of
maintena nce, which were much cheaper such as
preventive maintenance.
- - - - - - -
- -- - -- -
In addition, people in this era classified
maintenance as a function of the production system.

- -----
Maintenance History

-Term terotechnology introduced.


-Recognition of need to present
equipment failures.
-Models for preventive

maintenance developed. -Increased aware


-Environment ness of:
-Safety
-Quali ty
Fix 1hc oquipmcnl -Need for reliable
when ii breaks -Reduct ion in equipment.
cos ts.

Ti me
Pre-Wo rld Wur II Po st-World Wur II 1980 Onwards

Figure 2.2 Maintenance History


(Adapted From Shenoy, Bhadury 1998)
Purpose of Maintenance

• Attempt to maximize performance of


production equipment efficiently and
regularly
• Prevent breakdown or failures
• Minimize production loss from failures
• Increase reliability of the operating
systems
Maintenance History

Nowaday s, increased awareness of such issues as


environment safety, quality of product andservices
makes maintenance one of the most important
functions that contribu te to the success of the
industry.

--- - - - - - - ---
World-class companies are in
continuous need of a very well organised
maintenance programme to compete world-wide
-
What is Maintenance?

Maintenance is defined as:

1. The work under taken in order to keep or restore a


facility to an acceptable standard.
What is Maintenance?

2. The combination of activities by which


a facility is kept in, or restored to a
state in which it can perform its
acceptable standard
What is Maintenance?

• All actions necessary for retaining an


item, or restoring to it, a serviceable
condition, include servicing, repair,
modification, overhaul, inspection and
condition verif ication
• Increase availability of a system
• Keep system's equipment in working
order
Maintenance Definition

British Standard Glossary of terms (3811:1993)


defined maintenance as:

the combination of all technical and administrative


actions, including supervision actions, intended to
retain an item in, or restore it to, a state in which it
can perform a required function.
Maintenance Definition

maintenance is a set of organised activities that are


carried out in order to keep an item in its best
operational condition with minimum cost acquired.
Maintenance Activities

Activities of maintenance function could be either


repair or replacement activities, which are
necessary for an item to reach its acceptable
productivity condition and these activities, should
be carried out with a minimum possible cost.
What is Maintenance?
What are the main Types of Maintenance?

Accordi ng to maintenance information availability

(1) (2) (3)


Complete Incomplete Without
Information information information
Planned Planned Unplanned
1

Preventive M. Corrective M. Corrective M.


70 °/o 20°/o (or Emergency)
10°/o
M a intenance Works

Planned Unplanned

> 70 % < 30 %

PM overhaul M inor repairs Breakdown

> 50 % > 20 % < 20 % < 10 %

Typical Work (man-hour) distribution in engineering industries


Maintenance Works

Planned > 85 % Unplanned < 15 %

PM Overhaul Minor repairs Breakdown

> 70 % > 15 % < 10 % <5%

Typical work effort (man-hour) distribution in critical industries (such as gas,


oil, steam , power equip ment)
=========- -====-!.
What are th e main Policies of Maintenance?

1. Breakdown/ corrective maintenance


2. Preventive maintenance
a. Time-based preventive maintenance
- Pure t ime (calendar) based
- Used (running) t ime based
b. Condition-based preventive maintenance
" Predictive mainte nance PdM"
3. Opportu nity mainte nance
4. Fault f inding
5. Design modif icat i on
6. Over haul or Capital mainte nance
Principle Objectives in Maintenance
• To achieve product quality and customer
satisfaction through adjusted and serviced
equipment
• Maximize useful life of equipment
• Keep equipment safe and prevent safety
hazards
• Minimize frequency and severity of interruptions
• Maximising production or increasing facilities
availability at the lowest cost and at the highest
quality and saf ety standards
• Reducing downtime
Maintenance Objectives

• Improving spares stock control.


• Improvi ng equipment efficiency and reducing
scrap rate.
• Minimising energy usage.
• Optimising the useful life of equipment.
• Providing reliable cost and budgetary control.
• Identifying and implementing cost reductions.
Maintenance Objectives

• Must be consistent with the goals of


production (cost, quality, delivery ,
safety)
• Must be comprehensive and include
specific responsibilities
Maintenance Objectives
PLANT

Maximising Production

Usage
-- M
A
I
-
Reduce Breakdown s

Reduce Downtime
Minimising E nergy
N
Optimi sing Useful Life
T Improving Equipment
of Equipment E - t
Efficiency

Budgetary Control
Providing
- N
A
N
- t
Improving Inventory
Control

-
Optimisi ng Resour ces
Utilisation
- E
Implem enting Cost
Reduction
Problems in Maintenance
• Lack of management attention to
maintenance
• Little participation by accounting in analyzing
and reporting costs
• Difficulties in applying quantitative analysis
• Difficulties in obtaining time and cost
estimates for maintenance works
• Difficulties in measuring performance
Problems Exist Due To:
• Failure to develop written objectives and
policy
• Inadequate budgetary control
• Inadequate control procedures for work order,
service requests etc.
• Infrequent use of standards
• To control maintenance work
• Absence of cost reports to aid maintenance
planning and control system
Maintenance Costs

• Cost to replace or repair


• Losses of output
• Delayed shipment
• Scrap and rework
Types of Maintenance

• Maintenance may be classified into four categories:


• (some authors prefer three categories- scheduled
and preventive maintenances are merged)

• Corrective Maintenance (CM)


• Scheduled maintenance
• Preventive Mainten ance (PM)
• Predicti ve Maintenance (PDM) (Condition-based)
Run to Failure Maintenance (RTF)
It is the oldest type of maintenance.

The required repair, replacement, or restore action


performed on a machine or a facility after the
occurrence of a failure in order to bring this
machine or facility to at least its minimum
acceptable condition.
Run to Failure Maintenance (RTF)
It is subdivided into two types:
- Emergency maintenance: it is carried out as fast
as possible in order to bring a failed machine or
facility to a safe and operationally efficient
condition.
- Breakdown maintenance: it is performed after
the occurrence of an advanced considered failure
for which advanced provision has been made in
the form of repair method, spares, materials,
labour and equipment.
Run to Failure Maintenance (RTF)
Disad vantages:

Its activities are expensive in terms of both direct and


indirec t cost.

Using this type of maintenance, the occurrence of a failure


in a component can cause failures in other components in
the same equipment, which leads to low production
availability.

Its activities are difficult to plan and schedule in


advance. ver
y
Run to Failure Maintenance (RTF)
This \pe of n1a intenance is useful in the fo l/01rving
situation s:

The failure of a component in a system is unpredictable.

The cost of perf orming run to failure maintenance activities


is lower than perf orming other activities of other types of
maintenance.

The equipment failure priority is too low in order to include


the activities of preventing it within the planned
maintenance budget.
Corrective or Breakdown
Maintenance

• Corrective or Breakdown maintenance


implies that repairs are made after the
equipment is failed and can not perform its
normal function anymore

• Quite justif ied in small factories where:


- Down times are non-c ritical and repair costs are
less than other type of maintenance
- Financial just ification for scheduling are not felt
Corrective Maintenance (C M )
In this type, actions such as repair, replacement, or
restore will be carried out after the occurrence of a
failure in order to eliminate the source of this
failure or reduce the frequency of its occurrence.

In the British Standard 3811:1993 Glossary of terms,


corrective maintenance is defined as:

the maintenance carried out after recognition and intended to


put an item into a state in which it can perform a required
function .
Corrective Maintenance (C M )
This type of maintenance is subdivided into three
types:

Remedial maintenance , which is a set of activities


that are perf ormed to eliminate the source of failure
without interrupting the continuity of the
production process.

The way to carry out this type of corrective maintenance is


by taking the item to be corrected out of the production line
and replacing it with reconditioned item or transferring its
workload to its redundancy.
Corrective Maintenance (C M )
Deferred maintenance, which is a set of corrective
maintenance activities that are not immediately
initiated after the occurrence of a failure but are
delayed in such a way that will not affect the
production process.

Shutdown corrective maintenance , which is a set of


corrective maintenance activities that are performed
when the production line is in total stoppage
situation.
Corrective Maintenance (C M )
The 1 1i I (Jbj of correcti' e 111(1 I e 1(1 1c c: are the
l ctives
systems, the eliminatio
maximi sation of the neffectiveness
of breakdow ns,
of theall elimination of
critical plant
unnecessary repair, and the reduction of the deviations from
optimum operating conditions.

The cliffe rence /J correctiv 1nc1int ena11ce


et\<veen e and
maintenance, 111c1intenan
JJ the failure should occur before
is that for theany corrective
corrective
action is taken.
reventi ve ce
Corrective 111aintenance is diffe rent fro 111 run to failure
n1c1i11te11c111ce in that its activities are plan ned and regularly
taken out to keep plant's machine s and equipment in
optimum operating condition.
Corrective Maintenance (C M )
The way to perform corrective maintena nce activities is by
conducting four important steps:

1. Fault detection .
2. Fault isolation.
3. Fault elimination .
4. Verification of fault elimination .

In the fault elimination step several actions could be taken


such as adjusting, aligning, calibrating, reworking,
removing, replacing or renovation.
Corrective Maintenance (C M )
Corrective maintenance has several prerequisites in
order to be carried out effectively:

Accurate identification of incipient problem s.


Effective planning which depends on the skills of the
plan ners, the availability of well developed maintenance
database about standard time to repair, a complete repair
proced ures, and the required labour skills, specific tools,
parts and equipment.
Proper repair procedures.
Adeq uate time to repair.
Verification of repair.
Disadvantages of Corrective
Maintenance
• Breakdown generally occurs inappropriate times
leading to poor and hurried maintenance
• Excessive delay in production & reduces output
• Faster plant deterioration
• Increases chances of accidents and less safety for
both workers and machines
• More spoilt materials
• Direct loss of profit
• Can not be employed for equipments regulated by
statutory provisions e.g. cranes, lift and hoists etc
Scheduled Maintenance
• Scheduled maintenance is a stitch-in-time
procedure and incorporates
- inspection
- lubrication
- repair and overhaul of equipments
• If neglected can result in breakdown
• Generally followed for:
- overhauling of machines
- changing of heavy equipment oils
- cleaning of water and other tanks etc.
Preventive Maintenance (PM)

It is a set of activities that are performed on plant


equipment, machinery, and systems before the
occurrence of a failure in order to protect them and
to prevent or eliminate any degradation in their
operating conditions.
Preventive Maintenance (PM)
British Standard 3811:1993 Glossary of terms
defined preventive maintenance as:

the maintenance carried out at predetermined


intervals or according to prescribed criteria and
intended to reduce the probability of failure or the
degradation of the functioning and the effects
limited.
Why Preventi've Maintenance should be done?

DTo Prevent Failure

DTo Detect Early Failure

DTo Discover a Hidden Failure


Preventive Maintenance (PM)

The advantage of applying preventive maintenance


activities is to satisfy most of maintenance
objectives.
Preventive Maintenance (PM)
Thefa ctors that affect the efficiency of this type of maintenance:

The need for an adequate number of staff in the maintenance


department in order to perform this type of maintenance.
The right choice of production equipment and machinery that is
suitable for the working environment and that can tolerate the
workload of this environment.
The required staff qualifications and skills, which can be gained
through training.
The support and commitment from executive man agement to the
PM programme.
The proper planning and scheduling of PM programme.
The ability to properly apply the PM programme.
Preventive Maintenance (PM)
It is good for those machines and facilities which
their failure would cause serious production losses.

Its aim is to maintain machines and facilities in


such a condition that breakdow ns and emergency
repairs are minimised.

Its activities include replacements, adjustments,


major overhauls, inspections and lubrications.
Preventive Maintenance (PM)
Researchers subdivided preventive maintenanc e into
different kinds according to the nature of its activities:

Routine maintenance which includes those maintenance


activities that are repetitive and periodic in nature such as
lubrication, cleaning, and small adjustment.

Running maintenance which includes those maintenance


activities that are carried out while the machine or
equipment is running and they represent those activities that
are performed before the actual preven tive maintenance
activities take place.
Preventive Maintenance (PM)
Opportunity maintenance which is a set of maintenance
activities that are performed on a machine or a facility when
an unplanned opportunity exists during the period of
perf orming planned maintenance activities to other machines
or facilities.

Window maintenance which is a set of activities that are


carried out when a machine or equipmen t is not required for
a definite period of time.

Shutdown preventive maintenance , which is a set of


preve ntive maintenance activities that are carried out when
the prod uction line is in total stoppage situation.
Advantages of PM
• Advantages:
- Improving equipment availability/reliability
- Reduces break down and thereby down time
- Lass odd-time repair and reduces over time of
crews
- Greater safety of workers
- Lower maintenance and repair costs
- Less stand-by equipments and spare parts
- Better product quality and fewer reworks and
scraps
- Increases plant life
- Increases chances to get production incentive
bonus
Preventive
maintenance

Condition Statistically and


based
reliability based

Ir

On line Time Use


based based
Predictive Maintenance (PDM)
Predictive maintenance is a set of activities that detect
changes in the physical condition of equipment (signs of
failure) in order to carry out the appropriate maintenance
work for maximising the service life of equipment without
increasing the risk of failure.

It is classified into two kinds according to the methods of


detecting the signs of failure:
Condition-based predictive maintenance
Statistical-based predictive maintenance
Predictive Maintenance (PDM)

Cond ition-based predictive maintenance depends on


continuous or periodic condition monitoring equipment to
detect the signs of failure.

Statistical-based predictive maintenance depends on


statistical data from the meticulou s recording of the
stoppages of the in-plant items and components in order to
develop models for predicting failures.
Predictive Maintenance (PDM)
The drawback of predictive maintenance is that it depends
heavily on information and the correct interpretation of the
information.

Some researchers classified predictive maintenance as a type


of preve ntive maintenance.

The main difference between preventi ve 111ut1i1t


maintenance
11c.11ll t
and u,)( ..)
predicti ve maintenance is that ... u 1<- " ' t
tf 1
11u111 1tc 11 "'X 111c. lc111utt tc ni l/J , 1llchines or ec1ui11
cleter111i11e the actual nzean ti111e /<) j( 1il ure whereas
JJre1enti\ e 1nc1i11te11c111ce dejJend'I ( ) l l inclu \t r ial a1t r u c.: "J c.:
'ltati \t i( "·
Predictive (Condition-based)
Maintenance
• In predictive maintenance, machinery
conditions are periodically monitored and this
enables the maintenance crews to take timely
actions, such as machine adjustment, repair
or overhaul
• It makes use of human sense and other
sensitive instruments, such as
- audio gauge, vibration analyzer, amplitude meter,
pressure , temperature and resistance strain
gauges etc.
Predictive Maintenance (Contd.)

• Unusual sounds coming out of a rotating


equipment predicts a trouble
• An excessively hot electr ic cable
predicts a trouble
• Simple hand touch can point out many
unusual equipment conditions and thus
predicts a trouble
Predictive (Condition-based) Maintenance
by monitoring key equipment parameters

•Vibration analysis
•Oil analysis
•Wear analysis
•Noise analysis
•Temperature analysis
•Pressure analysis
•Quality analysis
•Efficiency analysis -====== -
P red1ct1ve Ma 1ntena nce
Why PM is Preferred

1.The frequency of premature failures can


be reduced through proper lubrication,
adjustments and cleaning.

2.If failure can not be prevented periodic


inspections can help reduce its severity.
Maintenance
Cost
Total Maintenance Cost

Optimal Maintenance
Commitment
PROBABILITYMODELS FOR BREAKDOWNS
Example 16.16 The housewares plant of a chemical company has 15 identical molding machines that produce a
variety of molded products that generate a profit of $100 per machine per day. The machines fail according to a
Poisson distribution with an average of 2.2 machines down each day.
(a) What is the chance of having exactly three machines down on a given day?
(b) What is the expected amount of lost profit per day du.e to this Poisson failure rate of 2.2 per day?
(a)
. .
Since failures follow the .eoisson distribution, the probability of X machines failing onf1Ygiven day is:
A e- A
P(X) = x! .

where X = number of machines broken down =3


A= mean failure rate= 2.2iday
e - .2.718
(2.2)1e.u
P(X = 3) =
3! =.1966 = 20 percent chance
.(Note that the values may be calculated or taken from Appendix Das P(X =3) =P(X < 3) - P(X < 2) =
.8'19 - .623 =.196)
(b) The expected loss per day is:

E<X) =X • P(X)

where x = amount of loss= $100/machine-day


P(X) = mean value of distribution = 2.2 machines/day
Therefore, E(X) = 100(2.2) =$220/day
Determining the Size of Repair Crews

• Problem:
• A factory has 200 machines and the maintenance
engineer supervises the repair crews who repair
malfunctioning machines. The maintenance policy is
to repair the broken down machine and bring back in
production within 2 hours on the average. If average
breakdown rate is 3.5 machines/ hour and each repair
crew can repair 0.25 mac hine per hour on the
average. How many repair crews are required ?
Solution
The formula for average repair rate (µ) is
1
ts = - --------- or µ = 'A + 1/ ts
µ - A.
Where µ = repair rate
'A = arrival rate of malfunctioning machines
ts = average time arrivals in the system

Required average repair rate


µ = 3.5 + 1 I 2 = 4 machines I hour
No. of Crews = µ -T machines/hour a crew can repair
= 4 -T 0.25 = 16 repair crews required
Types of Maintenance
MAINTENANCE

PLA NNED UNPLA NNED


MA INTENANCE MAINTEi'llA NCE
(PROACTIV E) (REACTIVE )

EMERGENCY BREAKDOWN

PREDEC TJVE PR EVENTIVE IMPROVEME NT C ORRECTIVE


MAINTENAN C E MA INTENA NCE MAINTENANCE MA INTENA NCE

STATISTICAL CONDITION · ENGINEERING DEFERRED R EMEDIAL


· BASED BASED DESIGN · OUT
SERVICES

Shuilown Maintenance

WINDOW RU NlNG R OUTINE OPPORTU SHUf DOWN SIIUTDOWN


SHUfDOWN
NITY PREV F.NTIVE IMPROVEMENT
CORRECTIVE
:\laioteoaoce Plaooiog

Pre\·enuve Correcuve
maintenance maintenance

Predeteruuned Cond111on Planned Unplanned


maintenance monitoring correcltve correcti\·e

Calendar Op.time Periodic Predictl\·e


Continuous
based based Inspection maintenance

RBI
What are the main fac tors, which affect the selection of
._,,,_ Maintenance Policy?

••Manufacturing maintenance recommendation


• •System availability
• •Safety factors
••Production process
••Operating conditions
••Information availability
••Resource availability
••Operating & maintenance cost
••Down time cost rate
••Failure and repair characteristics
What is the effect of Maintenance Pol icy on
the Equipment Productivity ?
M aint e n ance M anagem ent Pyr a m id
tep 1
Establi h
perfonnance
obj ective and
tandard

tep 4 Step 2
Take corrective Measure actual
action to restore performance
Control
1he designed
Procc s
specifications

tcp 3
Compare actual
performance with
the desi2.ned

Four steps of the 1naintenance control process


Maintenance Strategy
Comparison
Resources/
Maintenance Technology Application
Advantages Disadvantages Requ ired
Strategy
Breakdown No prior Disruption of May need Example
Off ice copier
work production, labor/parts
required injury or death at odd
hours
Preventive Work can Labor cost, Need to Plant
be may replace obtain relamping,
scheduled healthy labor/parts Machine
components for repairs lubrication
Predictive Impending Labor costs, Vibration, IR Vibration and
failures can costs for analysis oil analysis of
be detected detection equipment or a large
& work equipment and purchased gearbox
scheduled services services
Maintenance Strategy
Implementation
Percentage of Maintenance Time by Strategy
100°/o

Predictive
60°/o

40°/o

20o/o

001o

1 2 3 4 5 6 7 8 9 10
Year

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