Maintenance policies

Maintenance Policies
(1)

(5)

Failure-Based
Reactive (ReM):
- RTF
- CM
- BD (2)
:: Time-Based

Total-Based
Global (GM):

Preventive (PM):
- Calendar:
Weekly
Monthly
::
- Running:
1000 R.H.
1000 K.M.
::

(3)
Condition-Based
Predictive (PdM):
- Oil analysis
- Vibration analysis
- Temperature analysis
- Pressure analysis
- Wear analysis
- Efficiency analysis
::

- Optimization Approach

- TPM
::
(4)
Risk-Based
Proactive (PaM):
- RCFA
- FMEA \ FMECA
- HAZOP
- RCM \ RCM2
- RBI ::

Classification of maintenance policies.

ME091301 and
Maintenance
Management
[Venkatesh 2003, Waeyenberg
Pintelon
2004, and Gomaa et al. 2005]

Objective of maintenance policies

Top 5 Objectives

(1)
To
correct
failures/
Hazards
Reactive
Policy <5%

(2)
To
prevent
failures/
Hazards

(3)
To
discover
hidden
failures/
Hazards

(4)
To
detect
early
Failures/
Hazards

Preventive Policy >80

(5)
To
Minimize
the risk of
failures/
Hazards
Proactive
Policy >15

Preventive & Predictive Maintenance

Maintenance
Policies
Preventive
Maintenance
Direct Preventive
Maintenance
Fixed Time
Maintenance

Essential Care

Corrective
Maintenance

Indirect Preventive
Maintenance/ Condition
Based Maintenance (CBM)

Subjective
Condition
Monitoring

Predictive Maintenance

Objective
Condition
Monitoring

Breakdown
Maintenance

Planned
Maintenance

Off-line
Monitoring
On-line
Monitoring
ME091301 Maintenance Management

12

Objective of PM
To minimize the number of breakdowns on critical
equipment
To reduce the loss of production that occurs when
equipment failures take place
To increase the productive life of all capital equipment
To acquire meaningful data relative to the history of all
capital equipment.
To permit better planning and scheduling of required
maintenance work
To promote better safety and health of work force
To maximize the return on capital investment
14

Maintenance policies
Maintenance Policies
(1)

(5)

Failure-Based
Reactive (ReM):
- RTF
- CM
- BD (2)
:: Time-Based

Total-Based
Global (GM):

Preventive (PM):
- Calendar:
Weekly
Monthly
::
- Running:
1000 R.H.
1000 K.M.
::

(3)
Condition-Based
Predictive (PdM):
- Oil analysis
- Vibration analysis
- Temperature analysis
- Pressure analysis
- Wear analysis
- Efficiency analysis
::

- Optimization Approach

- TPM
::
(4)
Risk-Based
Proactive (PaM):
- RCFA
- FMEA \ FMECA
- HAZOP
- RCM \ RCM2
- RBI ::

Classification of maintenance policies.

[Venkatesh 2003, Waeyenberg and Pintelon 2004, and Gomaa et al. 2005]

What Is Reliability-Centered Maintenance?

One definition:
Reliability Centered Maintenance is a maintenance strategy that
logically incorporates the optimum mix of reactive, preventive,
condition based and proactive maintenance practices.
Reliability-Centered
Maintenance

Reactive
Maintenance
Small items
Non-critical
Unlikely to fail
Redundant

Preventive
Maintenance
Subject to wear-out
Consumable replacement
Known failure pattern

Condition-Based
Maintenance
Random failure Pattern
Not subject to wear
PM induced failure

Proactive
Maintenance
RCFA
FMEA, FMECA
RBI

Other definitions
Reliability-Centered Maintenance is a process
used to determine what must be done to
ensure that any physical asset continuous to
do what its users to do in its present operating
context. (John Moubray, RCM)
Reliability-centered Maintenance as a process
to establish the safe minimum levels of
maintenance. (John Moubray, RCM II)

What is SAE JA 1011 said about RCM?

Reliability-Centered Maintenance (RCM)Any RCM process shall
ensure that all of the following seven questions are answered
satisfactorily and are answered in the sequence shown as follows:
1.
2.
3.
4.
5.
6.
7.

What are the functions and associated desired standards of

performance of the asset in its present operating context
(functions)?
In what ways can it fail to fulfill its functions (functional failures)?
What causes each functional failure (failure modes)?
What happens when each failure occurs (failure effects)?
In what way does each failure matter (failure consequences)?
What should be done to predict or prevent each failure (proactive
tasks and task intervals)?
What should be done if a suitable proactive task cannot be found
(default actions)?

RCM goals and logic

RCM Goals

RCM Logic

Ensure realization of inherent safety and

reliability of the equipment

Determine the function of

the system/component

Restore equipment to required levels when

deterioration occurs

Define what is a functional

failure

Obtain the information necessary for design

improvements where inherent reliability is
insufficient

Evaluate the consequences

of failure

Accomplish these goals at a minimum total

life cycle cost

Assign a maintenance task

to prevent the failure

RCM History
1960 - FAA and airline task force
1965 - United Airline decision diagram
1968 (Maintenance Steering Group) MSG-1
1970s - Military Interest
1980s - Industry Interest

1990s - NASA Facilities

2000 - Accepted as a Best Practice by Federal
Facilities Council

Why Perform RCM?

Financial benefits are derived from the following:
Reduced maintenance expenses due to elimination of maintenance
tasks
Application of Age Exploration techniques to expand time between
tasks
Reduction in the amount of reactive maintenance performed by:
Modifying existing procurement/installation practices and techniques
Identifying systems for condition monitoring by using RCM analysis
Development of an acceptance criteria and commissioning

Indirect benefits
Reduction in downtime
MRO (maintenance, repair, operation) reduction
Fewer compliance issues

Failure Modes And Effects Analysis (FMEA)

A failure analysis conducted in the design phase
of an equipment or system; also used as a tool for
analysis in Reliability Centered Maintenance
(RCM).
The FMEA contains:

Description of Failure Modes

Cause and Effects of failure
Probability of Failure
Criticality of Failure
Corrective/Preventive Measures

Selecting maintenance approach

One of the main goal of RCM analysis is to select most
appropriate maintenance technique for any set of
equipment or systems. Each maintenance action may be
classified into following category:
Corrective maintenance
Preventive maintenance

Scheduled discards
Scheduled restoration
Redundancy
Checkouts

Condition based maintenance

Inspections
Monitoring

Selecting maintenance approach

Machine/System

Run-to-failure applications
Use RTF if Unexpected Failure is Acceptable
in Terms of Impact on:
Safety/Security
Capacity
Life Cycle Cost
Regulatory
Probability of Failure is Low

Preventive maintenance tasks

Strong correlation between are/cycles and
probability of failure
Frictional wear
Corrosion
Simple component replacement
Regulatory

Condition Based Maintenance (CBM)

CBM is the use of advanced technology to sense machinery
operating characteristics such as:
vibration,
temperature,
pressure, etc.
and to compare the measured values of these characteristics with
historical data or other pre-established criteria to assess
machinery condition.
CBM permits condition based rather than time based initiation of
the maintenance effort to correct any problems identified.

Total Productive Maintenance

(TPM)
Tahun 1971 Siichi Nakajima seorang pelopor dari konsep Total productive
Maintenace (TPM) di Jepang.

TPM adalah proses manajemen yang dikembangkan untuk meningkatkan

produktivitas dengan membuat proses lebih handal dan tidak boros.

Tujuan awal dari TPM:

Continuously improve all operational conditions, within a production
system; by stimulating the daily awareness of all employees (by Seiichi
Nakajima, Japan, JIPM)

Total Productive Maintenance

(TPM) -1
Total Productive Maintenance (TPM) sebagai metode untuk
meningkatkan ketersedian mesin melalui pemanfaatan yang lebih
baik dari maintenance dan sumber daya produksi.
Operator pada mulanya tidak dianggap sebagai anggota team
maintenance, didalam TPM operator dilatih untuk banyak
melakukan kegiatan harian maintenance sederhana dan
menemukan jika terjadi kesalahan.
TPM menyediakan sebuah pendekatan life cycle menyeluruh
untuk management peralatan yang dapat memperkecil
kegagalan peralatan, kerusakan produksi dan kecelakaan.

Total Productive Maintenance

(TPM) -2
Total Productive Maintenance (TPM) mempunyai 3
tujuan dasar:
1. Zero produk cacat.
2. Zero peralatan yang gagal secara tak terencana
3. Zero kecelakaan.

TPM mempunyai 8 pilar aktivitas:

1. Focused improvement (Kobetsu Kaizen) - Continuously even small steps of
improvement.
2. Planned Maintenance - It focuses on Increasing Availability of Equipments
& reducing Breakdown of Machines.
3. Initial Control - To establish the system to launch the production of new
product & new equipment in a minimum run up time.
4. Education & Training - Formation of Autonomous workers who have skill &
technique for autonomous maintenance.
5. Autonomous Maintenance (Jishu Hozen) - It means "Maintaining one's
equipment by oneself". There are 7 Steps in & Activities of Jishu Hozen.
6. Quality Maintenance (Hinshitsu Hozen) - Quality Maintenance is
establishment of machine conditions that will not allow the occurrence of
defects & control of such conditions is required to sustain Zero Defect.
7. Office TPM - To make an efficient working office that eliminate losses.
8. Safety, Hygiene & Environment - The main role of SHE (Safety, Hygiene &
Environment) is to create Safe & healthy work place where accidents do
not occur, uncover & improve hazardous areas & do activities that preserve
environment.

Dasar untuk TPM beraktivitas adalah 5S:

Seiri (Sorting out the required or not required items);

Seition (Systematic Arrangement of the required items);
Seiso (Cleaniness);
Seiketsu (Standardisation);
Shitsuke (Self Discipline).

The Pillars & their details

a) Efficient Equipment Utilisation
b) Efficient Worker Utilisation
c) Efficient Material & Energy Utilisation