Maintenance

Management

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Agenda
 Definition
 Current Practices
 Types of Failures
 Maintenance Strategies
 Types of Maintenance
 Repair and Maintenance

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 Definition
 Maintenance is the routine and recurring process
of keeping a particular asset in its normal
condition so that it can deliver the excepted
performance or service without any loss or
damage

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Definition
 Maintenance Management all the activities that
determine the maintenance objectives, strategies
and implementation by means of maintenance
planning, control, supervision and considering
economical aspects

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 Current Practice
 Maintenance is the actions associated with
facilities after it is broken
 While maintenance should be actions taken to
prevent a facility from failing or to repair normal
degradation to keep it in proper working order
 However, data obtained in many studies indicates
that facilities’ owners do not expend the necessary
resources to make maintenance in proper working
order
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Current Practice
 Rather, they wait for the failure to occur and then
take whatever actions are necessary to repair or
replace the facility
 Nothing lasts forever and all facilities have
predefined life expectancy or operational life
 For example, equipment may be designed to
operate at full design load for 5,000 hours and
may be designed to go through 15,000 start and
stop cycles
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 Failures
 Failure – inability to produce work in appropriate
manner
 Equipment / machine failure on production, failure
of power supply, air-conditioned system, computer
network, photocopy machine
 Vehicle failure – brake, transmission, engine,
cooling system
 Building, bridge, road failure, etc.

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Types of Failures
 Failures can be grouped into three categories,
understanding these is critical when assigning
maintenance tasks:
 Induced
 Intermittent
 Wear out

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 Types of Failure (Induced)
 Induced failures are a result of an outside force
causing the failure mode
 For instance, extra loads on a given structure
 Monitoring may help detect these potential failures
 Failure must be recognized and analysis performed
to determine the root cause
 As such, we acting proactively and making the
transition into a Reliability-Based Maintenance

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Types of Failure (Intermittent)

 Intermittent failures can happen at any time
"random” , time between failures cannot be
determined
 Failures can best detect through process and
predictive maintenance monitoring
 Many plants find that preventive maintenance are
not effective in determining the onset of failure in
either induced or intermittent failures and,
therefore, a waste of capital
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 Types of Failure (Wear Out)
 Wear-out failures have a known time between
failures and they occur when the useful life of a
component is expended
 These types of failure modes are often detectable
through process and predictive maintenance
monitoring
 However, time-based refurbishment usually proves
to be the most effective maintenance strategy

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Failure Against Life Cycle

 The failure rate against a facility life cycle can be
represented as follow:

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 Failure Against Life Cycle
 The initial period of the curve is characterized by
high failure rate which may be linked to poor
design, poor installation, or misapplication
 The infant mortality period is followed by a nearly
constant failure rate period known as useful life
 There are many theories on why components fail in
this region, most acknowledge that poor O&M
often plays significant role

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Failure Against Life Cycle

 It is also generally agreed that exceptional
maintenance practices encompassing preventive
and predictive elements can extend this period
 The wear-out period is characterized by a rapid
increasing failure rate with time
 In most cases this period encompasses the normal
distribution of design life failures

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Maintenance in Service Industry
 Hospital
 Restaurants
 Transport companies
 Banks
 Hotels and resorts
 Shopping malls / retail
 Gas station

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Questions?
 Why do we need maintenance?
 What are the costs of doing maintenance?
 What are the costs of not doing maintenance?
 What are the benefits of maintenance?
 How can maintenance increase profitability of
company?

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 Maintenance Objectives
 Ensure that facilities and their associated services
are in a safe condition
 Ensure that facilities are fit to use
 Ensure that the condition of the facilities meets all
statutory requirements
 Maintain the value of facilities stock
 Improve the quality of a facility

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Maintenance Strategies
 Maintenance can be divided into the following
strategies:
 Reactive (day-to-day repair)
 Preventive, which includes cyclic and condition-based
maintenance
 Predictive, modernization and maintenance which include
additional works needed as a result of new legislation and
regulations

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Maintenance Strategies (Reactive)
 Reactive maintenance is basically the “run it till it
breaks” maintenance mode
 No actions or efforts are taken to maintain the
facility to ensure design life is reached
 Studies indicate this is still the predominant mode
of maintenance in the United States, more than
55% of maintenance resources and activities of an
average facility are still reactive
 Emergency or nonplanned
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Maintenance Strategies (Reactive)

 If our maintenance program is purely reactive, we
will not expend manpower dollars, we could view
this period as saving money
 In reality, during the time, we are spending more
dollars associated with capital cost because, while
waiting for the facility to deteriorate, we are
shortening the life of the facility resulting in more
frequent replacement

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Maintenance Strategies (Reactive)
 Advantages
 Low cost

 Less staff

 Disadvantages
 Increased cost due to unplanned downtime of a facility

 Cost involved with repair or replacement of components

 Possible secondary damages from failure of main

components
 Inefficient use of staff resources

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Maintenance Strategies (Reactive)

 Breakdown maintenance, in this system the
facility is allowed to function / operate till no
failure occurs; ie no maintenance work is carried
out in advance to prevent the failure
 As long as the facility is functioning at a minimum
acceptable level, it is assumed to be effective
 This approach is ineffective and extremely
expensive due to: poor planning and incomplete
repair
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Maintenance Strategies (Preventive)
 Preventive maintenance is a maintenance program
committed to the elimination or prevention of
corrective and breakdown maintenance
 A comprehensive preventive maintenance program
involves periodical evaluation of critical
equipment to detect problems and schedule
maintenance tasks to avoid degradation in
operating conditions
 Planned or scheduled
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Maintenance Strategies (Preventive)

 Preventive maintenance defined as actions
performed on a time or run-based schedule that
detect or mitigate degradation of a component or
system with the aim of sustaining or extending its
useful life through controlling degradation to an
acceptable level
 Expending the necessary resources to conduct
maintenance activities intended by the designer,
life is extended and reliability increased
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Maintenance Strategies (Preventive)
 Dollars are saved over that of a program just using
reactive maintenance
 Studies indicate that this savings can amount to as
much as 12% to 18% on the average
 Preventive maintenance will run facility more
efficiently resulting in dollar savings
 While we will not prevent catastrophic failures, we
will decrease the number of failures

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Maintenance Strategies (Preventive)

 Advantages
 Cost effective in many capital-intensive processes

 Adjustment of maintenance periodicity

 Increased component life cycle

 Reduced equipment or process failure

 Disadvantages
 Catastrophic failures still likely to occur

 Includes performance of unneeded maintenance

 Potential for incidental damage to components in

conducting unneeded maintenance
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Maintenance Strategies (Predictive)
 Predictive maintenance is a management
technique that uses regular evaluation of the
actual operating conditions of equipment,
production systems to optimize total operation
 Condition-based or reliability

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Maintenance Strategies (Predictive)

 Predictive maintenance defined as measurements
that detect the onset of system degradation (lower
functional state), thereby allowing causal stressors
to be eliminated or controlled prior to any
significant deterioration in the component physical
state
 Results indicate current and future functional
capability

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Maintenance Strategies (Predictive)
 Basically, predictive maintenance differs from
preventive maintenance by basing maintenance
need on the actual condition rather than on some
preset schedule
 Preventive maintenance is time-based
 Activities such as changing lubricant are based on
time, no concern is given to the actual condition
and performance capability of the oil
 It is changed because it is time
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Maintenance Strategies (Predictive)

 Unusual sounds coming out of a rotating
equipment predicts a trouble
 An excessively hot electric cable predicts a trouble
 Simple hand touch can point out many unusual
equipment conditions and thus predicts a trouble
 Cracks on the Skelton of a buildings or steel rust
show problems that need to be fixed

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Maintenance Strategies (Predictive)
 Advantages
 Predictive maintenance is used to define needed
maintenance task based on quantified condition
 Eliminate catastrophic failures
 Allows for preemptive corrective actions

 Decrease in equipment or process downtime.

 Decrease in costs for parts and labor

 Better product quality

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Maintenance Strategies (Predictive)

 Disadvantages
 Increased investment in diagnostic equipment

 Increased investment in staff training

 Savings potential not readily seen by management

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 Maintenance Strategy Model
 Different dimensions should be looked at when
planning maintenance work

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Maintenance Strategy Model

(Decision Diagram)

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 Types of Maintenance
 Other View

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Types of Maintenance
 Maintenance Decision

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 Repair
 Generally, the maintenance scheduling embraces
the following activities:
 Inspection
 Repair
 Overhauling

 Hence the term repair reflect the time duration

consumed to perform the corrective action
 Based on the time the repair may be minor like
adjustment of something or major
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Repair and Maintenance

 Repairs
 Repair activities are reactive
 Breakdowns and malfunctions occurs when system in use
 Cost is high

 Preventive Maintenance
 Based on regular scheduled inspection
 Performed before failure and during ideal time

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 Repair and Maintenance
Trade-off between Repair and Maintenance
 At minimum level of preventive maintenance

(remedial policies)
 Do repair only when breaks occur
 Cost of breakdowns, interruptions of service and repair is
high

 As the preventive maintenance efforts increased,

breakdown and repair costs decreased
 At some point, the total maintenance cost reached
its minimum value
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Repair and Maintenance

Trade-off between Repair and Maintenance
Annual Cost

Minimum Total
Maintenance Cost
Total
Maintenance
Costs
Minimum Preventive
Level of Maintenance
Preventive Cost
Maintenance Breakdown
and Repair
Cost
Low Degree of Preventive Maintenance High
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 Repair and Maintenance
How Speedy Should Repairs Be?
Cost

Minimum
Total Cost
of Repairs

Cost of Repair
Crews &
Spare Parts
Cost of
Interruptions to
Service
0
Slow Speed of Making Repairs Fast
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Structural Health Monitoring

 SHM is defined as the use of in-situ, non-
destructive sensing and analysis of structural
characteristics, including the structural response,
for detecting changes that may indicate damage or
degradation
 It is a move from visual inspection to data
collection base inspection and monitoring

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 Structural Health Monitoring
 Basic components of SHM

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Structural Health Monitoring

 SHM aims to provide quantitative data on the real
conditions of a structure and detect the
appearance of degradations
 By installing a number of sensors, continuously
measuring parameters relevant to the structural
conditions and other environmental parameters
 SHM can be used for load estimation (e.g. traffic,
wind) and validate design assumptions regarding
the static and dynamic behavior of structures
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 Design for Life-Cycle
 The promotion of a design that decreases a facility
cost over its life-cycle
 The ASCE is currently preparing guidelines for
promoting design for life-cycle
 The life cycle cost (LCC) of an asset is defined as
the present value of the total cost of that asset
over its operating life, including initial, occupation,
operating costs, and the cost or benefit deriving
from disposal of the asset at the end of its life
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Design for Life-Cycle

 The broad objectives of a life cycle costing may be:
 To enable more effective investment decisions, taking
into account all costs that may arise from it
 To consider the impact of all costs, rather than just
capital costs
 Too provide information that can contribute to the more
effective management of the completed facility
 To assist in the evaluation of alternative solutions to
specific design problems

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 Design for Deconstruction
 The usage and end of life impact of construction
activities on the ecosystem are to be accessible at
the design stage
 Design activities must be beneficial to the
ecosystem during building usage and end-of-life
 The focus of AEC practitioners has shifted from the
traditional methods of end-of-life building disposal
to modern methods such as deconstruction

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Design for Deconstruction

 DfD could serve multiple purposes, material
recovery for building relocation, component reuse,
material recycling and remanufacture
 DfD are more concerned with building relocation
and component reuse rather than recycling or
manufacturing
 More challenge is to design buildings that can be
deconstructed and its components reused with
minimal reprocessing
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 Design for Deconstruction
 DfD Factors

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