Preventive Maintenance Planning

1
 Maintenance policies
Maintenance Policies
(1) (5)
Failure-Based Total-Based
Reactive (ReM): Global (GM):
(3)
- RTF - Optimization Approach
Condition-Based
- CM
Predictive (PdM):
- BD (2) - TPM
- Oil analysis
:: Time-Based ::
- Vibration analysis
Preventive (PM): - Temperature analysis (4)
- Calendar: - Pressure analysis Risk-Based
Weekly - Wear analysis Proactive (PaM):
Monthly - Efficiency analysis - RCFA
:: :: - FMEA \ FMECA
- Running: - HAZOP
1000 R.H. - RCM \ RCM2
1000 K.M. - RBI :: ????
::
Classification of maintenance policies.
[Venkatesh 2003, Waeyenberg and
ME091301 PintelonManagement
Maintenance 2004, and Gomaa et al. 2005] 2
 Preventive & Predictive Maintenance
Maintenance
Policies

Preventive Corrective
Maintenance Maintenance

Indirect Preventive Predictive Maintenance

Direct Preventive
Maintenance/ Condition
Maintenance Breakdown
Based Maintenance (CBM)
Maintenance
Fixed Time
Maintenance
Subjective Objective
Condition Condition Planned
Monitoring Monitoring Maintenance

Off-line
Essential Care Monitoring

On-line
Monitoring
ME091301 Maintenance Management 3
 Definition
 Essential Care adalah kompilasi dari proses yang
akan mencegah terjadinya kegagalan.
 Lubrication, alignment, balancing, cleaning, and
operating procedures, adjustments and installation
procedures. Essential Care dapat mencegah kegagalan
(memperpanjang umur peralatan).
 Fixed Time Maintenance Peralatan diganti
secara berkala pada interval waktu yang tetap.
Pemeliharaan tepat waktu dapat mencegah
terjadinya kegagalan (tanpa memperpanjang
umur)

ME091301 Maintenance Management 4

 Definition
 Objective Objective methods are for example
vibration analysis, ultrasonics, and temperature-,
pressure-, voltage- and ampere readings.
 Subjective inspections are look, listen, feel and
smell
 Preventive Maintenance is essential care and
fixed time maintenance together. Both essential
care and fixed time maintenance PREVENTS (both
prevent) FAILURES, while Conditions Monitoring
only DETECTS FAILURES EARLY.
ME091301 Maintenance Management 5
Preventive Maintenance Overview

ME091301 Maintenance Management 6

 Preventive Maintenance
Why PM should be done?

To prevent To detect To discover

equipment failures early failures hidden failures

Time-Directed Condition-Directed Failure Finding

Maintenance (TD) Maintenance (CD) (FF)

ME091301 Maintenance Management 7

 Failure
 What is failure?
 Suatu kondisi yang tidak sesuai dengan yang
diinginkan
 what does the relationship between failure
rate and life time of equipment look like?
 Bathtub curve
 Do all equipments have same failure pattern?
 NO!

ME091301 Maintenance Management 8

Lifetime Failure Rates

ME091301 Maintenance Management 9

Failure Patterns

Traditional Concept

Distinct aging during useful life

No infant and wear out

Low failure follow

by constant hazard

Constant failure

Infant failure follow

by constant hazard

ME091301 Maintenance Management 10

Failure Patterns
Q: How the failure patterns affect maintenance people?

A: Major challenge facing maintenance people is?

To learn what techniques are used
To decide which method are worthwhile and
which are not in their own organizations.

Right choices, it is possible to improve asset performance

and at the same time contain and even reduce the cost of
maintenance.

Wrong choices, new problems are created while existing

problems only get worse.
ME091301 Maintenance Management 11
 Total Maintenance Cost
Cost

Total Maintenance Cost

PM Cost

Down Time Cost

CM Cost

Best level
PM level Reliability

ME091301 Maintenance Management 12

2 hal yang perlu dipertimbangkan

Q: apa tujuan PM?

Q: Bagaimana
Mengidentifikasi PM?

ME091301 Maintenance Management 13

 Tujuan PM
 Untuk meminimalkan jumlah kerusakan peralatan kritis
 Untuk mengurangi hilangnya produksi yang terjadi saat
terjadi kegagalan peralatan
 Meningkatkan produktifitas seluruh Capital equipment
 Untuk mendapatkan data yang berarti terhadap
catatan/history semua Capital equipment
 memungkinkan perencanaan dan penjadwalan
pemeliharaan yang lebih baik
 Memastikan keselamatan dan kesehatan kerja yang
lebih baik
 Untuk memaksimalkan pengembalian investasi modal

ME091301 Maintenance Management 14

 Karaktristik Plant yang membutuhkan program PM
 Manfaat mesin dan peralatan yang rendah karena
pemberhentian kerja yang tak terjadwal

 Waktu tunggu atau waktu menganggur operator

yang tinggi peralatan atau mesin downtime

 Kenaikan biaya perbaikan peralatan karena

rutinitas kerja seperti pelumasan, cleaning

 Turunnya produktifitas karena kurang perawatan

yang memadai

ME091301 Maintenance Management 15

 PM: An Example

 First, hitung jumlah kerusakan yang terjadi

untuk setiap kebijakan PM.
 Next, hitung biaya yang diperlukan secara
rinci, biaya perawatan preventif, dan biaya
total untuk setiap kebijakan PM.
 Finally, identifikasi kebijakan yang
meminimalkan total biaya per satuan waktu
(misal, per minggu).
ME091301 Maintenance Management 16
 Expected Number of Breakdowns
n
Bn  N( p n )  B(n 1) p1  B(n  2) p 2  ...  B1p (n 1)
1

where:
Bn = perkiraan jumlah kerusakan untuk masing-
masing kebijakan PM
pn = Peluang terjadinya gangguan setiap
periode n
N = jumlah mesin dalam kelompok

ME091301 Maintenance Management 17

 Example: PM Frequency
 It costs $6,000 to perform PM on a group of four
machines.
 The cost of down time and repairs, if a machine
malfunctions between PM inspections, is $8,000.
 How often should PM be performed to minimize
the expected cost of malfunction and the cost of
PM?

(The machines’ breakdown history is on the next

slide.)
ME091301 Maintenance Management 18
 Example: PM Frequency
 Machine Breakdown History

Weeks Probability That a

Between PM Machine Will Malfunction
1 0.2
2 0.3
3 0.5

ME091301 Maintenance Management 19

Example: PM Frequency
n
Bn  N( p n )  B(n 1) p1  B(n  2) p 2  ...  B1p (n 1)
1

B1 = 4(0.2) = 0.800
B2 = 4(0.2 + 0.3) + 0.8(0.2) = 2.160
B3 = 4(0.2 + 0.3 + 0.5) + 2.16(0.2) + 0.8(0.3) = 4.672

ME091301 Maintenance Management 20

 Example: PM Frequency
Exp. Weekly
PM Exp. Number Exp. Weekly Total
Every Number of BDs Cost of Cost Weekly
n Wks. Of BDs per Wk. BDs of PM Cost
1 0.800 0.800 $6,400 $6,000 $12,400
22 2.160 1.080 8,640 3,000 11,640
3 4.672 1.557 12,456 2,000 14,456

The policy that minimizes total weekly cost is:

perform PM every 2 weeks.

ME091301 Maintenance Management 21

 Assignment#2 (Individual)
 Find a paper in journal concerning to the
preventive maintenance.
 Write a summary with the maximum length of
10 pages A4 format.
 Prepare for 15 minute presentation

ME091301 Maintenance Management 22

 References
 Norman Gaither & Greg Frazier, Operations
Management, Edition 9, Academic Internet
Pub Inc, 2001.
 GMM or CMS, Slides prepared by Dr. Attia
Hussien Gomaa, Engineering service -
American University in Cairo (AUC).
 Anthony Kelly, Maintenance Systems and
Documentation, Elsevier, 1st Edition 2006.

ME091301 Maintenance Management 23