Maintenance Strategies

Introduction
Maintenance Strategies
On-Failure Maintenance
Fixed Time Maintenance
The Need for More Strategies
The Bathtub & Other Curves
Predictive Maintenance
Design Out Maintenance
Selecting Maintenance Strategies
Key Points

Wolfson Maintenance - 2000

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Introduction
From day one, equipment and plant must be maintained if it is to
fulfil its function for a useful life. This can be achieved using one of
the four key maintenance strategies:
On-Failure Maintenance
Fixed Time Maintenance
Predictive Maintenance
Design Out Maintenance

z
z
z
z

Each of these strategies has a place within an optimized

maintenance plan (see Fig 1), but the distribution of the mix will
depend upon many factors, including;
The equipment to be maintained
The operational context - both in terms of production and
the prevailing environmental conditions, for example sub-sea
The maintenance resources available
Health and Safety compliance
General practicalities
Cost

z
z
z
z
z
z

Each maintenance strategy has advantages when implemented

correctly, but conversely, disadvantages when implemented
incorrectly. For example, we would maintain the indicator bulbs on
an auto using on-failure maintenance as this is both cost effective
and practical. However, we would select an alternative to the onfailure strategy when considering the maintenance of the auto
braking system.
Note: Many differing terms are used to describe the various
strategies, planned maintenance, preventive maintenance, etc.
and these will be discussed in the relevant sections.

On-Failure

Condition Based
Failure Mode
Parameter Trend

Maintenance
Plan

Monday

48920

53677

X
X

Tuesday

Wed

Thursd
Friday

63019

33325

42964

84666

33571

10748

96725

42876

Fixed Time

Fig 1: The Optimum Maintenance Plan

Design Out

Maintenance Strategies
Complete the table below for each of the four maintenance
strategies. Enter a definition for the strategy, for example OnFailure Maintenance - fix it when it breaks, and list as many
advantages for this strategy when implemented correctly. In
addition list as many disadvantages as possible for when this
strategy is implemented incorrectly. Also, provide one example
of equipment relevant to your field that you would maintain
using this strategy.

Strategy
On-Failure

Definition

Fix it when
it breaks

Advantages
(when
implemented
correctly)

Cheap

Disadvantages
(when
implemented
incorrectly)

High spares
stock levels

Equipment
you would
maintain

Table 1: Maintenance Strategies

Fixed Time

Predictive

Design Out

On-Failure Maintenance
Definition:
Maintain equipment when it has failed to fulfil its
function.

Comments:
Replacement, or repair of equipment after failure, is the default strategy - eventually failure will occur if
nothing else is done.
On-failure maintenance is sometimes called corrective maintenance, a term which is unspecific and can be
applied to other strategies and hence is better avoided. Unfortunately on-failure maintenance encourages the
fire-fighting syndrome - respond fast and work furiously - with its attendant problems.

Advantages:
z
z
z

it requires no pre-care of the plant

it requires little management apart from
organizing labor and stores
if applied correctly, it can be very cost effective

Disadvantages:
z
z
z
z
z

there is no warning of failure - this can present

a significant safety and/or environmental risk
uncontrolled plant outage will result stoppages occur unexpectedly
there will be production losses or delays these will inevitably result in increased cost
there is a need to provide standby plant if
higher levels of availability are required - this
can lead to higher build costs
it requires a large standby maintenance team as you have no indication of what will fail, you
need a standby team ready to repair any of
your equipment
secondary or consequential damage may occur
- a bearing failure may lead to the failure of the
shaft, followed by the pump, etc, which will
lead to higher costs of spares and longer
repair times
there is a requirement for a large spares stock
to cater for any kind of failure that may occur

Monday

Thursd
Friday

48920

X
X

Wed

Maintain equipment based upon fixed time - either

calendar based, run hours based, or number of
equipment cycles based.

53677

Tuesday

Definition:

63019

33325

42964

84666

33571

10748

96725

42876

Fixed Time Maintenance

Comments:
If we wish to improve on a fire fighting situation dominated by on-failure maintenance, it is possible to
implement the fixed time maintenance strategy. That is, attempt to maintain the equipment before failure and
thereby prevent failure.
Replacement, or repair at a fixed time interval before failure, is the strategy most commonly applied to reduce
on-failure maintenance. The simple planning structure for manpower and spares makes this strategy
attractive for the management of maintenance and gives the reasoning behind the very common name
planned preventive maintenance. Safety related checks are also often carried out on a fixed time basis.

Advantages:
z
z
z

it reduces failures (compared to the on-failure

strategy)
it uses the workforce cost-effectively with
planned work schedules
it allows work to be planned well in advance

Disadvantages:
z
z
z
z

the maintenance activity and associated costs

will increase
it can only be applied effectively on fixed time
intervals where the deterioration is age related
(see overleaf)
the actual maintenance activity can sometimes
cause failures itself
may be replacing a component that still has
useful life

The Need For More Strategies

As mentioned previously, on-failure maintenance, whilst applicable
in some instances, is not appropriate for most industrial plant
where, for example, high levels of safety and availability with
reduced cost are required.
Fixed-time maintenance is often an improvement upon the
breakdown strategy, but it is only applicable to age related
deterioration.
For example, if historical analysis of a plain bearing illustrates that
it will fail due to general wear once every two years, then it would
be sensible to replace the bearing before wear-out occurs, perhaps
every 23 months. However, this is not always the case.

The Bathtub & Other Curves

Run in
Phase

Useful Life Phase

Wear Out
Phase

Failure Rate

The curve shown (Fig 2), the typical

Bathtub curve, illustrates the
classic profile of failure rate against
time for equipment. As can be seen
there is a run-in phase where there
are a large number of failures, often
known as high infant mortality. The
number of failures then reduces
during the normal level during the
running phase of the life cycle. Then
as the equipment ages and starts
to wear-out the number of failures
start to rise again, this is known as
the wear-out phase.

Decreasing
Failure Rate

Constant Failure Rate

Increasing
Failure Rate

Operating Time (component age or life)

Fig. 2: The Bathtub Curve

The failures of equipment that illustrate wear-out can also be shown on a graph as a failure distribution against
time (the total operating time before failure):

Number of Failures

Ideal time to replace = 2.4 years

Fig 3 illustrates a possible failure

distribution for 10 motors. As can be
seen, all the failures occur between 2.5
and 3.5 years of operation, and so the
ideal time to replace these motors would
be after 2.4 years of operation. This would
eliminate the failures, whilst keeping
replacement costs to a minimum.

Years of operating life

Fig. 3: Failure Distribution for 10 Motors

However, if the failure distribution of these motors was as shown in Fig 4, then there is no ideal time to
replace the motors.
For example, if you replace the motors
z
z
z

after 5 months then the cost of replacement is too high,

after 2.4 years then the cost of replacement and failure is too high,
after 3.6 years then the cost of failures is too high,

and so there is no ideal time for replacement. In other words, fixed time maintenance would not be
appropriate.

When to Replace ?

Number of Failures

After 2.4 years

Replacement
& failures too
high

After 5 months

Replacement
costs too
high

After 3.6 years

Failures too
high

Years of operating life

Failure Rate

Fig. 4: Alternative Failure Distribution for 10 Motors

Failure Rate

Failure Rate

Failure Rate

Unfortunately, studies have shown that plant

equipment fails in many ways that are not
related to wear-out, and in fact the bathtub
curve is only applicable to some ways in
which the equipment fails. Fig 5 illustrates
some other failure rate profiles that are
typical for plant equipment. As can be seen,
there is no clear wear-out phase for these
profiles, and as such, no ideal time to
maintain the equipment using fixed time
maintenance. This in turn means that
alternative strategies are required if
maintenance is to reduce both the number
of failures, and the overall costs of
operating the plant.
Operating Time (component age or life)

Fig. 5: Alternative Failure Rate Curves

Predictive Maintenance
Failure Mode
Parameter Trend

Definition:
Maintain equipment based upon its known condition.

Comments:
Maintenance on inspection or monitoring is an attractive concept, in that the maintenance action will only be
performed when knowledge of the equipment indicates that failure to fulfil its function is imminent. Though
the maintenance work will often be corrective, the ability to plan the work also makes it preventive in nature.

Advantages:
The advantages of utilizing the Predictive
Maintenance strategy are many, some of which are
not so tangible - such as increased motivation of the
workforce through increased competency. The main
advantage to Predictive Maintenance is that
impending equipment failure can be detected, which
in turn provides the following benefits:
z
z
z

equipment can be shut-down before severe

damage occurs
alternatively, equipment can be run to failure if
desired
production can be modified to extend the unit
life, for example, decrease the load on
equipment so that it can continue to run until
the next planned plant shutdown
the required maintenance work can be
planned, with labor organized, spares
assembled, etc.

All of the above will increase safety, plant output and

availability, and will lead to improvements in the final
product quality.
In addition, as a result of the additional information
collected during the inspection or monitoring process:
z

the real cause of failure can be analyzed, for

example, if the vibration indicates an
impending bearing failure, reasons for that
failure mode can be investigated - this would
be more difficult to identify following a
catastrophic failure resulting in a pile of broken
components
following identification of the real root cause
for failure, it is possible to plan in design
modifications if required

Disadvantages:
Different organizations will present differing reasons
for not implementing Predictive Maintenance, but the
only disadvantage to the strategy is that:
z

it is costly if implemented incorrectly

That is, if condition monitoring is undertaken without

an understanding of the equipment, and not as a part
of an overall maintenance plan, then it is likely that it
will fail, result in expenditure, and lose credibility
within the organization. To succeed, Predictive
Maintenance must be implemented correctly within
the improvement context and against a complete
understanding of the equipment, its failure modes,
and root causes.

Design Out Maintenance

Definition:
Design, or redesign, equipment to eliminate the root
cause of failure and resulting failure modes so as to
eliminate or minimize the need for maintenance.

Comments:
Redesigning a unit is also part of the maintenance function. The other strategies discussed involve a degree
of repetition and they are concerned with responding to or anticipating failures in an effective manner. In
contrast, redesigning to avoid failure is, or should be, a one-off activity. There is, therefore, considerable scope
for plant improvement by the application of design out maintenance.

Advantages:
z
z
z
z

it is a one-off maintenance activity

it reduces failures
it will lead to increased production
it will remove or reduce the need for
maintenance

Disadvantages:
z
z
z
z

large design changes can be costly

plant outages may be required to effect design
changes
unless root causes of failure are fully
understood, changes may be ineffectual, or
potentially detrimental
there are sometimes unknown knock-on
effects of design changes that can cause
further difficulties later on

Selecting Maintenance Strategies

For each of the cases shown in the table below, mark the most
appropriate maintenance strategy or strategies that should be
implemented.

Airplane wing / falls off due to poor fixtures

Air handling unit / belts worn out - general wear
Car indicator bulb / ceases to work due to element failure
Pump / seal leaks
Plain bearing / general wear
Computer / failed mother board
Pump bearing / misaligned during installation
Pump impeller / wear due to cavitation
Pump impeller / general wear
Fan rolling element bearing / fan out of balance
Vibrating feeder / incorrect operator settings
Director's office air handling unit / not known

Table 2: Selecting Maintenance Strategies

Out
ign
Des

tive
dic
Pre

ime
ed T
Fix

On-

Equipment / Why it fails

Fa i

lure

Maintenance Strategy

Key Points
z

All four maintenance strategies are required to make an

effective Maintenance Plan

All four maintenance strategies have advantages when

implemented correctly

All four maintenance strategies have disadvantages when

implemented incorrectly

The appropriate strategy can only be chosen when the

reasons for equipment failures are fully understood

Notes

Notes

Task 1 - Maintenance Strategies

Solutions to this task can be found in the main body of text and there are several correct answers, however
an example solution is shown below.

Strategy
On-Failure

Fixed Time

Definition

Fix it when
it breaks

Conduct
maintenance
at regular
intervals

Advantages
(when
implemented
correctly)

Cheap

Disadvantages
(when
implemented
incorrectly)

Equipment
you would
maintain

etc

High spares
stock levels
etc

Headlights

Table 1: Maintenance Strategies

Can be
planned for
etc

Predictive

Maintain
based upon
known
condition

Redesign t0
eliminate
root cause
of failure

Spot a
potential
failure

Less
maintenance
required

etc

etc

Unnecessary
replacement
of parts

Costly if
implemented
incorrectly

etc

etc

Oil change

Design Out

Automobile
tires

Could be
expensive
etc

Dyson
vacuums

Task 2 - Selecting Maintenance Strategies

For some situations it is possible to address the way equipment fails through different maintenance strategies.
Operational requirements will dictate the most appropriate strategy to select.

Airplane wing / falls off due to poor fixtures

Air handling unit / belts worn out - general wear
Car indicator bulb / ceases to work due to element failure

Pump / seal leaks

Plain bearing / general wear
Computer / failed mother board

Pump bearing / misaligned during installation

Pump impeller / wear due to cavitation
Pump impeller / general wear
Fan rolling element bearing / fan out of balance
Vibrating feeder / incorrect operator settings
Director's office air handling unit / not known

Table 2: Selecting Maintenance Strategies

Out
ign
Des

tive
dic
Pre

ime
ed T
Fix

On-

Equipment / Why it fails

Fa i

lure

Maintenance Strategy

9 9
9
9
9 9
9 9
9
9