TOPIC 9

Maintenance Management
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Maintenance Management
Introduction
Principles
To preserve and keep an asset in order to enable
its continued use and function, running at high
capacity, best operational condition, produce
quality products at lowest/minimum cost
acquired within the safety prescriptions.
To maximize the facility performance,
improve the maintenance resource
productivity, over its design service life,
without unforeseen renewal or major repair
activities.

Activities
Are related with repair, replacement and service of
components or some identifiable group of
components in a plant operations.
Necessary to continue to operate at a specified
availability for a specified period with to reach its
acceptable productivity condition and should be
carried out with a minimum possible cost. 2
Maintenance Management
Introduction
History
Many old machines are operating, the spare
part problem are arising.
Some times it is difficult to find spare parts
for equipment and if it is possible to find
them, they are usually very expensive and
must be paid on foreign currency.

Solutions
Due to long lead times of supply of spares, it is
common that the spare part inventory is
growing bigger than necessary.
A very essential part in maintenance
management is developing countries to reduce
the need of spare parts, as well as to maintain
the minimum level of shock to save foreign
currency, but still keeping the productivity
high. 3
Maintenance Management
Introduction
Importance
To responsible for the smooth and efficient
working of the industrial plant and helps in
improving the productivity.
To keep the machines/equipment in their
optimum operating conditions.
To maintaining and improving the operational
efficiency of the plant facilities and hence
contributes towards revenue by decreasing
the operating cost and improving the quality
and quantity of the product being
manufactured.
As a service function it is related with the
incurrence of certain costs; employment of
maintenance staff, other minor
administrative expenses, investment in
maintenance equipment and inventory of
repair components/ parts and
maintenance materials. 4
Maintenance Management
Introduction
If absence of MM
May lead to frequent machine breakdown and
failure of certain productive centres/services
which in turn would result:
- stoppages of production activities
- idle man and machine time,
- dislocation of the subsequent operations
- poor quality of production
- failure to meet delivery dates of product supply
- industrial accidents; endangering the life of workers
Loss of production
Rescheduling of production.
Materials wastage
Need for overtimes,
Need for work subcontracting.
For maximum manpower utilization workers
may need alternative work due to temporary
work shortages.

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Maintenance Management
Functions of Maintenance

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Maintenance Management
Maintenance Objectives

PLANT & ASSET

Maximising Reduce Breakdowns

Production

Minimising Energy Reduce Downtime

Usage

Optimising Useful Life Improving

of Equipment Equipment Efficiency

Providing Budgetary Improving Inventory

Control Control

Optimising Resources Implementing Cost

Utilisation Reduction

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Maintenance Management
Maintenance Objectives
Objectives
Maximising production or increasing
facilities availability at the lowest cost and
at the highest quality and safety standards.
Reducing breakdowns and emergency
shutdowns.
Optimising resources utilisation.
Reducing downtime.
Improving spares stock control.
Improving 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.
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Maintenance Management
Reasons for Maintenance
Reasons
Physical Integrity
To keep the assets in good working order so as to
minimize disruptions and downtimes.
Risk Management
To keep the assets in a state of good repair for the
owners health and safety.
Aesthetic Preservation
To keep the assets from deteriorating in
appearance and becoming unsightly.
Responsible Stewardship
To ensure that the assets achieve their full potential
service life.
Duty of Care
To satisfy a legislated duty that is owed to owners,
occupants and guest on the property.
Duty to Mitigate
To prevent unnecessary damage to assets that may
result in their premature failure.

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Maintenance Management
Types of Maintenance

i. Preventive maintenance
a. Periodic maintenance
- Time Based Maintenance (TBM)
b. Predictive maintenance
- Condition Based Monitoring (CBM)
- Risk Based Inspection (RBI)
- Reliability Centred Maintenance (RCM)

ii. Corrective maintenance

a. Planned Corrective
b. Unplanned Corrective

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Maintenance Management
Types of Maintenance
i. Preventive maintenance
It is a daily maintenance (cleaning, inspection, oiling and re-tightening), design to retain the healthy
condition of equipment and prevent failure through the prevention of deterioration, periodic inspection
or equipment condition diagnosis, to measure deterioration.

a. Periodic maintenance
TBM consists of periodically inspecting, servicing and cleaning equipment and replacing parts to prevent
sudden failure and process problems

b. Predictive maintenance
Method in which the service life of important part is predicted based on inspection or diagnosis, in order
to use the parts to the limit of their service life.
CBM is the process of determining the condition of machinery while in operation.
RBI is a process that identifies, assesses and maps industrial risks (due to corrosion and stress
cracking), which can compromise equipment integrity in both pressurized
equipment and structural elements.
RCM is a process to ensure that systems continue to do what their users require in their present
operating context. It is generally used to achieve improvements in fields such as the establishment of
safe minimum levels of maintenance.

ii. Corrective maintenance

It improves equipment and its components so that preventive maintenance can be carried out reliably.
Equipment with design weakness must be redesigned to improve reliability or improving
maintainability.

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Maintenance Management
Types of Maintenance

Preventive Maintenance

Why PM should be done?

To prevent To detect To discover

equipment failures early failures hidden failures

RBI/
TBM CBM
RCM

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Maintenance Management
Types of Maintenance

Corrective Maintenance

How CM should be done?

Deferred Shutdown Corrective

Maintenance Maintenance

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Maintenance Management
Types of Maintenance

Corrective Maintenance

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Maintenance Management
Types of Maintenance

Maintenance Structures

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Maintenance Management
Types of Maintenance

Maintenance Structures

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Maintenance Management
Maintenance Strategy

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Maintenance Management
Maintenance Challenges

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Maintenance Management
Maintenance Challenges

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Maintenance Management
Reliability

Definition

Probability a machine part/system/component to function properly

under stated conditions for a reasonable/specified length of time.
Reliability deals with the estimation, prevention and management of
high levels of "lifetime" engineering uncertainty and risks of failure.
Reliability is theoretically defined as the probability of success, as the
frequency of failures; or in terms of availability, as a probability derived
from reliability, testability and maintainability.
Reliability = 1 Probability of Failure

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Maintenance Management
Sustainability

Definition

Is the process of designing or operating systems such that they use energy
and resources sustainably.
In other words, at a rate that does not compromise the natural
environment, or the ability of future generations to meet their own needs.

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Maintenance Management
Sustainability

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Maintenance Management
Reliability vs Sustainability

What is the difference between reliability & sustainability?

Sustainability

Reliability

Example: Electrical supply

The electrical supply is reliable to get 24*7 supply of electricity.
But if the mechanisms that are used to generate electricity are leading to
degradation of environment then, even though having 24*7 supply
Therefore it is reliability in supply of electricity, BUT its not sustainable.
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Maintenance Management
Asset Management

Definition

Is a systematic and synchronized process of deploying, operating, maintaining,

upgrading, and disposing of assets optimal, sustainable and cost-effectively or
ineffectively over their life cycle to accomplish organizations strategic plans.
Apply to both tangible assets such as buildings and to intangible assets such as human
capital, or humans in general intellectual property, and goodwill and financial assets.

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Maintenance Management
Asset Management Life Cycle

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Maintenance Management
Facility Management

The management of buildings, physical plant and services.

Is a professional management discipline focused upon the efficient and effective
delivery of support services for the organizations that it serves.

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Maintenance Management
Facility Management

Encompasses multiple disciplines to ensure functionality of the built

environment by integrating people, systems, place, process, and technology.
On a day-to day level, effective facilities management provides a safe and efficient
working environment, which is essential to the performance of any business
whatever its size and scope. 27
Maintenance Management
Facility Management

Advantages Challenges
Prevents failure before Delay to report problem from user-
occurrence. failure of machine
Preserves and enhances User to be reluctant to put request
equipment reliability on official manner
Reduced down time Delay regarding approval/payment
Conservation of assets and long Prolonged procurement process
lifetime Lack of support on emergence issue-
Reduced repair costs understanding from user
Ensures proper functioning of Ageing asset management-cost on
equipment safety features repair and maintenance
Absence of signed contact 28
Maintenance Management
Asset Integrity Management

Design Technical
Integrity Integrity

Operational
Integrity

Asset Integrity is the ability of an asset to perform its required function effectively
and efficiently whilst protecting health, safety and the environment.
Asset Integrity Management to manage the integrity over the life cycle of an asset. 29
Maintenance Management
Asset Integrity Management

1. Rotating equipment 2. Static equipment

Rotating equipment is mechanical Static equipment is equipment that is
equipment that is used to move stationary and that do not move any
substances. This could be gas, liquid or substances, but are still helpful in many process
solid. The major rotating equipment is: operations. Typical static equipment is:
Pumps Heat Exchangers
Compressors Pipes
Turbines Tanks/Vessels
Blowers Separators
Gears Hydro Cyclones
Engines Scrubbers
Generators Valves

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Maintenance Management
Asset Integrity Management

Defects in design, process, quality, or part application, which are the

underlying cause of a failure or which initiate a process which leads to failure.

A mechanical, chemical, physical or other process that results in asset

degradation.

i. Corrosion viii. Wear

ii. Fatigue ix. Fretting
iii. Corrosion Fatigue x. Elevated Temperature
iv. Erosion Corrosion xi. Cavitation Damage
v. Stress Corrosion Cracking xii. Brittle Fracture
vi. Hydrogen Embrittlement xiii. Ductile Fracture
vii. Galling 31
Maintenance Management
Asset Integrity Management

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Maintenance Management
Maintenance Cost

The costs are directly

related to the performance
of the maintenance works

Losses due to maintenance

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Maintenance Management
Maintenance Cost

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Maintenance Management
Maintenance Philosophy

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Maintenance Management
Maintenance Philosophy

The MTTF/Bathtub curve indicates that a new machine has a high probability of
failure, because of installation problems, during the first few weeks of operation.
After this initial period, the probability of failure is relatively low for an extended
period of time.
Following this normal machine life period, the probability of failure increases
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sharply with elapsed time.
Maintenance Management
Maintenance Philosophy

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Maintenance Management
Code of Standard

ISO/TC 267, Facility Management

BS 8536:2010, Facility Management Briefing Code of Practice
ISO/DIS 41001, Facility management - Management systems

API 580, Risk-Based Inspection

API 581, Risk-Based Inspection Technology
PAS 55, Optimal Management of Physical Assets
ISO 55000, Asset management - Overview, principles and terminology

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Maintenance Management
Total Productive Maintenance (TPM)
Definition
A system of maintaining and improving the integrity of
production and quality systems through the machines,
equipment, processes, and employees that increased
efficiency and to optimize costs/business value to an
organization.
Focuses on keeping all equipment in top working
Equipment Maintenance
condition to avoid breakdowns and delays in
Technique
manufacturing processes.

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Maintenance Management
Total Productive Maintenance (TPM)

Pillars of TPM

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Maintenance Management
TPM vs TQM

TPM vs TQM

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Maintenance Management
Failure Modes & Effect Analysis (FMEA)
Definition
Is a structured approach to discovering and preventing
potential failures that may exist/before occur within
the design of a product, system or process.
Failure Modes are the ways in which a process can fail.
Effects are the ways that these failures can lead to
waste, defects or harmful outcomes for the customer.
Equipment Maintenance
Is designed to manage; identify, prioritize and limit
Technique
these failure modes effectively and reduce risks.
Is focused on preventing problems, enhancing safety by
assessing its risk of failure and increasing customer
satisfaction.

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