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Predictive Maintenance
Workshop
An Introduction to
Maintenance
Practices
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Before We Begin
Ask questions at any time!
Please turn your cell phone to vibrate.
If you must take a call, please feel free but we ask
that you take it outside the seminar room.
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IMPORTANCE OF MAINTENANCE STRATEGY
Technology / Solution
Maintenance Strategy
Improved Business Performance
Plant Owner Business Objectives
Business objectives drive
the maintenance strategy,
which in turn drives the
technologies and
solutions applied.
Maintenance strategy
definition and development
is a critical success factor in
the customers value chain.
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Reactive Maintenance: Often called run to failure. No repair or
maintenance actions are taken on machinery until the designed
life span is reachedor other variables cause the machinery to
fail.
Upside:
Lower upfront maintenance costs
Lower maintenance staff costs
Downside:
Unplanned, sometimes catastrophic, downtime and overtime
hours
Secondary damage to machines impacted by the failed
machine
Potentially higher capital costs as entire components may need
to be replaced
Machines control maintenance department
Maintenance Practices
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Preventive Maintenance (Proactive Calendar Based )
Also called Historical or calendar-based maintenance
Upside:
Increased equipment life
Reduced equipment or process failure
Flexibility with maintenance scheduling
Downside:
Fault free machines maintained unnecessarily could lead
to incidental problems with components
Overhaul reduces reliability of the machine (see the
bathtub curve)
More labor intensive than Reactive Maintenance
Maintenance Practices
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Maintenance Practices
Predictive Maintenance (Proactive Condition Based): Use of different
testing (vibration, thermography, oil analysis, ultrasound are the most
common) to understand machine condition and prevent failure
Upside
Allows preemptive action to increase equipment life
Increased equipment life
Reduced equipment or process failure
Reduced repair parts and labor costs
Increased safety
Reduced likelihood of catastrophic failures
Downside
Increased investment in diagnostic / test equipment
Increased investment in training and staff
Cost benefits not readily seen by management
May require top-down cultural change in maintenance approach
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CONDITION MONITORING
Condition Based Maintenance is the
maintenance initiated as a result of
knowledge of the condition of an
item from performing inspections
with condition monitoring
technologies.
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Semi Critical Machines
General Purpose Machines
C
R
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Number of Rotating Machines
1
2
Critical Machines
1
PLANT ASSET CLASSIFICATION
3
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Asset Criticality Ranking
On the Asset Criticality Pareto Chart, natural break points appear to
segregate the assets into identifiable criticality classifications
For the most critical assets (typically 10-15% of assets), a
Reliability Centered Maintenance (RCM) approach is used
to determine the appropriate maintenance strategy.
Critical assets are assessed using Failure
Modes & Effects Analysis (FMEA) process.
Less Critical assets are assigned a
strategy using standard Templates
Non-Critical assets
Run-to-failure
Distribution of Assets
15%
C
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R
a
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k
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30% (typical) 50% (typical)
5%
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Highly Critical- Continuous online vibration,
Thermography, Lube oil Analysis, Ultrasonic
Technology, Process Variable Analysis.
Critical- Continuous online vibration measurement,
protection & Analysis, Thermography.
Mid Level Criticality- Periodic Vibration online
Scanning
Low Level Criticality- Periodic Vibration Scanning
Non critical- Run to failure.
TECHNOLOGY
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Advantages of a CM Program
Find the problem before it finds you!
Improved less expensive maintenance
Consistent and improved availability
Increase in production rate
Reduced maintenance costs
Extend asset life (less need for capitol
expenditure)
Reduce asset base i.e. spare parts
Increased product quality and consistency
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Potential cost savings
Cost of failure / poor efficiency
Lost revenue (downtime, lost customer confidence)
Energy cost
Replacement cost
Repair costs (especially labour)
Cost of scrap
Cost of cleanup and restart
Insurance premium
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The Maintenance Strategy defines how the assets failure
modes will be managed. This requires identifying the failure
modes, probability of failure and appropriate mitigation
plan.
The three alternative tools that can be applied for
maintenance Strategy Development are:
RCM ( Relibility Centred Maintainance) carried by teams
on only the most critical systems. An individual RCM analysis
may take 8 to 10 person-weeks to complete.
FMEA (Faliure Mode Effect Analysis) developed by single
analyst on critical systems and equipment. The use of FMEA
libraries helps fastrack this process.
Templates consist of standard maintenance strategies for
low criticality assets
Develop the Maintenance Strategy
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PM Optimization
This is a systematic review of routine Preventive Maintenance (PM)
tasks with reference to the ideal maintenance strategy .
Work plans are strengthened with improved procedures, fully
developed Bill-of-Materials, tools and parts kits
By optimizing existing PM tasks, the cost of the maintenance program
is reduced, while reliability remains high
Savings from the PM Optimization process can fully fund the
introduction of a Predictive Maintenance program
Typical results from PM Optimization:
30% of PM tasks can replaced by more cost effective Predictive
Maintenance tasks
30% of PM tasks can be deleted (no value)
30% of PM tasks need strengthening.
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Testing for PdM
Condition
Monitoring
Machine
watch
keeping &
Etc..
Temperature
Vibration
Electrical /
Power
monitoring
Process
Parameters
Acoustic
Oil analysis
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Thank You