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Mechanical Department
Step One: Know the cost of the asset, both to purchase and to
replace.
For inexpensive assets that are fast and easy to replace, it may be less expensive to
practice Fail and Replace than to incur labor costs to perform preventive
maintenance tasks.
Run to failure can also make sense if spare parts are cheap and readily available in
spare parts inventory, and if labor costs to repair or replace the asset are cheap.
Step Two: Know the labor costs associated with the life cycle of the
asset under consideration.
Maintenance labor costs vary widely depending on the tasks and type of skilled
labor required. Knowing what those labor costs are can help you make informed
decisions. You should be able to track and analyze the labor costs for:
Preventive maintenance (PM) tasks
Labor costs for the most common repairs to the asset when it breaks
Labor costs to replace it when it fails
Step Three: Know the downtime and related costs associated with
the asset failure.
Downtime costs include both labor costs to restore the asset to functional status
and secondary damage that may occur as a result of the asset failure.
Before deciding on a run to failure approach, consider potential secondary damage
complications. In many cases, the secondary damage resulting from the primary
asset failure may far exceed the cost and consequences of the original asset
breakdown. This could be due to:
Time detection: It is the time between the origin of the problem and its
detection. There is a relationship between detection time and total resolution
time: the sooner the fault is detected, in general, will have caused less
damage and will be easier and cheaper to repair.
Waiting time: It is the time between the failure communication and the
start of the repair. It includes the waiting time to have workers can address the
incidence, the paperwork needed to intervene (equipment stops, work order
request, obtain a work permit, equipment isolation, etc..)
Diagnosis of the breakdown: It is time for maintenance operator to
determine what is happening on the equipment and how to fix it.
Collection of tools and technical means: Once determined what to do,
the personnel responsible for the repair may need some time to put in the
intervention place the means needed.
Collection of spare parts and materials: It is the time until the
delivery of the materials needed to perform the intervention.
Breakdown service: It is the necessary time to fix the problem emerged, so
the equipment is ready to produce. This time is severely affected by the extent
of the problem, the knowledge and skills of personnel involved in their
resolution. To optimize this time, it is necessary to have a preventive
maintenance system to avoid powerful breakdowns, and also have an effective
staff, motivated and well trained.
Comparisons between design and actual capacity for various plant and
or process.
management include: