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Preventative Maintenance

Optimization
How to Review
Existing Maintenance Program?

Why, “PM Optimization”?

Maintenance Program
Apply PMO

Failure modes

2
PM Optimization Steps
STEP 1 - TASK COMPILATION
STEP 2 - FAILURE MODE ANALYSIS
STEP 3 - RATIONALISATION AND FAILURE MODE REVIEW
STEP 4 - FUNCTIONAL ANALYSIS
STEP 5 - CONSEQUENCE EVALUATION
STEP 6 - MAINTENANCE POLICY DETERMINATION
STEP 7 - GROUPING AND REVIEW
STEP 8 - APPROVAL AND IMPLEMENTATION
STEP 9 - LIVING PROGRAM
3

PM Optimization
STEP 1 - TASK COMPILATION (for New Plant)

Computerised Condition Memory and


Maintenance Monitoring Tradition
Management Rounds.
Systems.

Operator Lubrication
Rounds. Rounds.
Sources of Preventive Maintenance

Contractor Standard
Schedules. Vendor Operating
Maintenance Procedures
Manuals.

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PM Optimization
Existing
STEP 1- TASK COMPILATION Maintenance Program

Task Interval Trade

Task 1 Daily Operator


Task 2 Daily Operator
Task 3 6 Months Fitter
Task 4 6 Months Fitter
Task 5 Annual Electrician
Task 6 Weekly Operator
Task 7 Monthly Greaser
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PM Optimization
STEP 2 - FAILURE MODE ANALYSIS
Task Interval Trade Failure

Task 1 Daily Operator Failure A


Task 2 Daily Operator Failure B
Task 3 6 Months Fitter Failure C
Task 4 6 Months Fitter Failure A
Task 5 Annual Electrician Failure B
Task 6 Weekly Operator Failure C
Task 7 Monthly Greaser Failure A 6
PM Optimization
STEP 3 - RATIONALISATION AND FAILURE MODE REVIEW
Task Trade Failure Grouping the
data by
Task 1 Operator Failure A failure mode
Task 4 Fitter Failure A
Task 7 Greaser Failure A
Task 2 Fitter Failure B
Task 5 Electrician Failure B
Task 3 Operator Failure C
Add missing
Task 6 Failure C failure mode
Failure D

PM Optimization
Each failure
STEP 4 - FUNCTIONAL ANALYSIS establish the
function lost

Task Trade Cause Function Lost


(Failure)
Task 1 Operator Failure A Function 1
Task 4 Fitter Failure A
Task 7 Greaser Failure A
Task 2 Operator Failure B Function 1
Task 5 Electrician Failure B
Task 3 Fitter Failure C Function 2
Task 6 Operator Failure C
Failure D Function 1
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PM Optimization
STEP 5 - CONSEQUENCE EVALUATION
Task Trade Cause Function Effect

Task 1 Operator Failure A Function 1 Operation


Task 4 Fitter Failure A
Task 7 Greaser Failure A
Task 2 Operator Failure B Function 1 Operation
Task 5 Electrician Failure B
Task 3 Fitter Failure C Function 2 Hidden
Task 6 Operator Failure C
Failure D Function 1 Operation
9

PM Optimization
STEP 6 - MAINTENANCE POLICY DETERMINATION

Task Trade Cause Function Effect Policy Interval

Task 1 Operator Failure A Function 1 Operation Inspect Daily

Task 4 Fitter Failure A

Task 7 Greaser Failure A

Task 2 Operator Failure B Function 1 Operation No PM -

Task 5 Electrician Failure B

Task 3 Fitter Failure C Function 2 Hidden Test Annually

Task 6 Operator Failure C

Failure D Function 1 Operation Inspect Weekly


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PM Optimization
STEP 6 - MAINTENANCE POLICY DETERMINATION
In this step, each failure mode is analysed using Reliability Centered Maintenance
(RCM) principles.

This step establishes new or revised maintenance policies. During this step the
following become evident:

RCM
Failure Mode Principle Maintenance Policy

11

PM Optimization
EVIDENT FAILURE HIDDEN FAILURE
Is The Failure To The Operating
Yes ตรวจพบได้ ระหว่ าง Normal Operation NO
Crew During Normal Operations? HIDDEN-FAILURE
Does The failure Cause A Loss Of CONSEQUENCES
Function Or Secondary Damage
มีThat
ผลกระทบเรื $อง Safety
Could Have A Direct Adverse
NO Scheduled maintenance is required to
ensure the level of availability
Effect On Operating Safety?
Does The Failure Have A necessary to avoid exposure to a multiple
ส่ งผลกระทบโดยตรงกั บกําลัOnงการผลิต
Direct Adverse Effect failure.

YES
Operational Capability Detect ได้ ดCondition
Is There a Cost-Effective ้ วย
YES NO YES Monitoring Task To Detect
OPERATIONAL NON-OPERATIONAL Condition Monitoring
Potential Failure?
SAFETY CONSEQUENCES CONSEQUENCES (ECONOMIC) CONSEQUENCES (ECONOMIC) Condition
Mandatory PM performance is PM Performance is desirable if PM Performance is desirable Monitoring NO
required to reduce the risk of failure to cost is less than the total cost of if its cost of repair of Task
PM cost <operational
Production lostand+CM cost PMfailures
cost it<prevents.
CM cost Is There A Cost-Effective
an acceptable level. consequences those ลด Failure Rate ได้
YES Time Directed Task
repair of those failures it prevents. โดยใช้ TimeThe
To Reduce Based
FailureMaintenance
Rate?
IsDetect
There aได้ ด้วย
Cost-Effective IsDetect ได้ ด้วย
There a Cost-Effective Detect
Is There ได้ ด้วย
a Cost-Effective Time
NO
Condition Monitoring Task To Condition Monitoring Task To YES Condition Monitoring Task To Directed
Condition Monitoring YES Condition Monitoring Condition Monitoring
Detect Potential Failure? Detect Potential Failure? Detect Potential Failure? Task
ลด Failure
Is There Rate ได้
A Cost-Effective
NO
Condition
NO
Condition
Monitoring NO
YES โดยทํFailure
า Failure
FindingFinding
Task Task
Monitoring
Task Task
Failure
(Function
To Reduce The FailureTest)
Rate?

ลดIsFailure
There A Cost-Effective
Rate ได้ ลดIs There A Cost-Effective
Failure Rate ได้ Is There A Cost-Effective
ลด Failure Rate ได้ Finding NO
Time Directed Task Time Directed Task YES Time Directed Task Task
โดยใช้ Time BasedTheMaintenance YES โดยใช้ To
Time Based Maintenance โดยใช้ToTime
ReduceBased Maintenance Can The Failure
To Reduce Failure Rate? Reduce The Failure Rate? The Failure Rate?
YES ยอมรับ Failure ทีเ$ กิดขึนB ได้ หรือไม่
Be Tolerated
Time
NO NO Monitoring NO
Time NO
Task
Redesign Monitoring Run To Run To Run To
Task Redesign
Required Failure Failure Failure
Required
IMPACT IMMEDIATE IMPACT DELAYED 12
PM Optimization
STEP 6 - MAINTENANCE POLICY DETERMINATION คุ.มหรือไม5ที่จะทํา

• The elements of the documented maintenance program that are cost effective,
and those that are not (and need to be eliminated),
Change to CBM

• What tasks would be more effective and less costly if they were condition
based rather than overhaul based, ไม5รู.ว5าทําไปทําไม

•What tasks serve no purpose and need to be removed from the program,
Extend Interval
•What tasks would be more effective if they were done at different frequencies,
ใช. new technology

•What failures would be better managed by using simpler or more advanced


technology,
•What data should be collected to be able to predict equipment life more accurately,
แก. Design , Modify
•What defects need to be designed out. 13

PM Optimization
STEP 7 - GROUPING AND REVIEW
establishes the most efficient and effective method for managing the
maintenance of the asset given local production factors and other
constraints.

STEP 8 - APPROVAL AND IMPLEMENTATION

STEP9 - LIVING PROGRAM

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