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-Term terotechnology
introduced.
-Recognition of need to
present equipment
Development of
Maintenance
failures.
-Models for preventive
maintenance
developed. -Increased awareness
of:
-Environment
Fix the equipment -Safety
when it breaks -Quality
-Need for reliable
equipment.
-Reduction in costs.
Time
Pre-World War II Post-World War II 1980 Onwards
Disadvantages
Increased cost due to unplanned downtime of equipment.
Increased labor cost, especially if overtime is needed.
Cost involved with repair or replacement of equipment.
Possible secondary equipment or process damage from
equipment failure. Using this type of maintenance, the occurrence of
a failure in a component can cause failures in other components in the
same equipment, which leads to low production availability.
Run to Failure Maintenance (RTF)
This type of maintenance is useful in the following
situations:
Disadvantages
Catastrophic failures still likely to occur.
Labor intensive.
Includes performance of unneeded maintenance.
Potential for incidental damage to components in conducting
unneeded maintenance.
Corrective Maintenance (CM)
In this type, actions such as repair, replacement, or
restore will be carried out after the occurrence of a
failure in order to eliminate the source of this
failure or reduce the frequency of its occurrence.
1. Fault detection.
2. Fault isolation.
3. Fault elimination.
4. Verification of fault elimination.
Disadvantages
Increased investment in diagnostic equipment.
Increased investment in staff training.
Savings potential not readily seen by management.
Reliability Centered Maintenance
Reliability centered maintenance (RCM) magazine provides the following
definition of RCM: a process used to determine the maintenance
requirements of any physical asset in its opera
RCM is a systematic approach to evaluate a facilitys equipment and resources
to best mate the two and result in a high degree of facility reliability and cost-
effectiveness. RCM is highly reliant on predictive maintenance but also
recognizes that maintenance activities on equipment that is inexpensive and
unimportant to facility reliability may best be left to a reactive maintenance
approach. The following maintenance program breakdowns of continually
top-performing facilities would echo the RCM approach to utilize all available
maintenance approaches with the predominant methodology being predictive.
<10% Reactive
25% to 35% Preventive
45% to 55% Predictive.
Types of Maintenance
MAINTENANCE
PLANNED UNPLANNED
MAINTENANCE MAINTENANC
(PROACTIVE) E (REACTIVE)
EMERGENCY BREAKDOWN
Shutdown Maintenance
Result
-Increased availability performance & efficiency
-Decreased cost of maintenance
of
Maintenance Effectiveness
(Result
The number and frequency of asset
Measures)
failures by area of consequence.
Maintenance costs are another direct
measure of maintenance performance.
The maintenance functions impact on
asset availability is through minimizing
downtime attributed to maintenance.
There are several useful maintenance cost related measures:
Maintenance Cost: The target maintenance cost depends on the
asset and its operating context (how the asset is applied and used).
Maintenance Cost / Unit Output: The target maintenance cost
depends on the asset and its operating context (how the asset is
applied and used).
Maintenance Cost / Replacement Asset Value of Plant and
Equipment: This metric is a useful benchmark at a plant and
corporate level. The world class benchmark is between 2% and
3%.
Total Maintenance Cost / Total Manufacturing Cost: This metric
is a useful benchmark at a plant and corporate level. The world
class benchmark is <10% to 15%.
Total Maintenance Cost /Total Sales: This metric is a useful
benchmark at a plant and corporate level. The world class
benchmark is between 6% and 8%.
Useful key performance indicators associated with asset
downtime attributable to maintenance are:
Identification of the asset at the level in the asset hierarchy where the
work was performed.
Date, time and duration of the maintenance event.
An indication if failure has occurred: yes or no (no if proactive)
When failure has occurred, identification of the failure consequence:
{hidden, safety, environment, operational (product quality, throughput,
customer service, operating costs) or nonoperational involving only the
cost of repair only}
actual costs (labor, materials, services, etc)
process downtime (loss of production)
asset downtime (equipment out of service but process still able to
produce)
Maintainability
Defined as probability of restoration of a failed device or
equipment or asset t operational effectiveness within a specified
period of time through the prescribed maintenance operations.