ARE 524

Facilities Maintenance Management

November 2nd, 2003
COLLEGE OF ENVIRONMENTAL DESIGN

COLLEGE OF ENVIRONMENTAL DESIGN

Quantum
Leaps

Selecting Maintenance Tactics Process

Reengineering

Section 4 Continuous
Improvement
RCM TPM

Uptime
Strategies for Excellence in Control
Data Plan and
Measures Tactics
Maintenance Management Management Schedule

By: John Dixon Campbell

Strategy Management Leadership

Prepared By: Instructor World Class Maintenance

KAMAL A. BOGES # 210321 Dr. ABDULMOHSEN AL-HAMMAD 2

OUTLINE INTRODUCTION - 1/1

™ Armed with the maintenance strategic plan, it is

COLLEGE OF ENVIRONMENTAL DESIGN

COLLEGE OF ENVIRONMENTAL DESIGN

™ TACTICAL OPTIONS
™CONDITIONED-BASED MAINTENANCE set to do battle against the evils of breakdown
™PREVENTIVE MAINTENANCE ™ Having mandate, the strategic objectives,
guidelines principles or policies, and a plan of
™ THE COST OF TACTICS
improvement
™ But when get right down to the equipment, what is
the most right to carry out?
™ Actions and their timing are the tactics needed to
carry out the strategic maintenance plan and to
make the difference

3 4

1. TACTICAL OPTIONS – 1/5 TATICAL OPTIONS – 2/5

™ All available maintenance option for a plant
™ For a personal car, do you:
COLLEGE OF ENVIRONMENTAL DESIGN

COLLEGE OF ENVIRONMENTAL DESIGN

equipment and machinery should be known, and

™ Replace head lights at regular intervals? then decide which ones are the most appropriate
™ Wait to replace tires until they wear through? ™ The choices tend to be a blend of both actions and
™ Check car’s engine before replacing it? timing
™ Each system or component in the car has a 1. Run-to-failure– Maintenance is performed only
function, a failure mechanism, a consequences, after the equipment fails. (Electronic circuit
and some economic implications board and lights bulbs)
2. Redundancy - Redundancy is built into an
™ Some times, a failure left to occur then the
equipment system. If the primary unit fails, the
replacement carried out. This whenever the secondary unit is available. (Hydraulic pumps
consequences aren’t sever, easy, and cheap to used in aircraft)
replace
5 6

1
 TACTICAL OPTIONS – cont. - 3/5 TACTICAL OPTIONS – cont. – 4/5
6. Preventive maintenance – This is based typically on
3. Scheduled components replacement – At a either time or use factors ( kilometers, cycles, fuel
COLLEGE OF ENVIRONMENTAL DESIGN

COLLEGE OF ENVIRONMENTAL DESIGN

predetermined point, based on either elapsed time consumption). It is carried out by conducting
or use and regardless of its condition. Because the inspections, cleaning and other failure prevention
repair expense skyrockets if they run to fail. actions. Often records kept for trend analysis. This
(Electric wheel motors) is typical in process sectors where there are visual
4. Scheduled overhaul - Like the scheduled signs of wear and corrosion
replacement, the plant or equipment is stripped 7. Condition-base Maintenance- Maintaining plant and
and overhauled, based on a predetermined plan. equipment is based on its measured condition such
(Annual shutdown) as vibration, stress, contamination, electrical
5. Ad hoc maintenance – Is done on-the -fly or when measure and visual inspection
there is a production window. Many manufacturers 8. Redesign – Designing out maintenance is done
revert to this option when there is a sudden particularly for critical equipment where it is difficult
increase in required throughput to measure the condition or detect imminent failure.
7 8
(Car of 1940s vs. today car)

TACTICAL OPTIONS – 5/5 FAILURE AND AGE RELATIONSHIP 1/5

™ The difficulty comes in selecting the correct ™ There are six broad relationships between failure
COLLEGE OF ENVIRONMENTAL DESIGN

COLLEGE OF ENVIRONMENTAL DESIGN

maintenance tactic. Which action and schedule is

probability and advanced age, not just one or two
most appropriate when considering cost, plant
Least Likely
down time and risks? ƒ Worst old
™ It is essential to understand how the failure
ƒ Bathtub
happened and if there was any it could be
prevented it ƒ Slow aging
™ Maintenance is usually time-based but it is hard to
assure that a part is more likely to fail due to its ƒ Best new
age (car parts and body)
ƒ Constant
™ Recent research into equipment failure probability
and advanced age has shown some results ƒ Worst new
surprising. The most significant finding is that isn’t
Most Likely
a strong link at all 9
Conditional Probability of Failure 10

FAILURE PROBABILITY 2/5 FAILURE PROBABILITY 3/5

™ Worst old ™ Slow aging
COLLEGE OF ENVIRONMENTAL DESIGN

COLLEGE OF ENVIRONMENTAL DESIGN

ƒ Age related ƒ Steadily increasing probability of failure with age

ƒ Rapid increase in failures at a particular point of use ƒ Associated with corrosion or creep
ƒ The least common failure mechanism of all ƒ Usually when equipment is in contact with a product
ƒ Routine maintenance based on time is effective ƒ Use rebuild or component replacement tactics
ƒ Examples: crusher jaws, impellers tracks and liners ƒ Example: Pipes, tiers, clutches
™ Bathtub ™ Best new
ƒ High probability of failure at beginning and end of ƒ Not age-related, except at beginning of life
its life ƒ Age-based routine maintenance generally ineffective
ƒ Two tactics, at least, are necessary to deal with ƒ As with all random mechanisms, on condition is the
early and end-of life problems best tactics
ƒ It is a combination of a “worst new” and “worst old” ƒ Example: hydraulics, penumatics
ƒ Example: Electromechanical system, HVAC 11 12

2
 FAILURE PROBABILITY 4/5 EQUIPMENT MAINTAINANCE - 5/5
™ Constant ™ This study, therefore, gives some important tips
COLLEGE OF ENVIRONMENTAL DESIGN

COLLEGE OF ENVIRONMENTAL DESIGN

ƒ Random failure, not age-related
ƒ Complex equipment system: electrical
ƒ Routine age-related maintenance is ineffective
ƒ Example: Ball bearings
™ Worst new
ƒ Most common failure mechanism for complex
equipment
ƒ Probability decline with age, perhaps because of
design, manufacture, construction, or management
ƒ Once the infant mortality problem is solved, routine
maintenance plays a minor role
ƒ Example: Electronics, avoinics
about how equipment should be maintained
ƒ Failure is not usually related directly to age or use
ƒ Failure is not easily predicted, so restorative or
replacement maintenance based on time or use
won’t normally help to improve the failure odds
ƒ Major overhauls can be a bad idea because it ends
up at a higher failure probability in the most
dominant patterns
ƒ Age-related component replacement may be too
costly for the same reason
™ Finally, knowing failure pattern only doesn’t tell
what maintenance tactics to use. But, in addition, an
economic study, a careful scrutiny data, and
13 sampling studies will assist the decision 14

CONDITIONED – BASED MAINTENANCE - 1/5 CONDITIONED – BASED MAINTENANCE - 2/5

™ Conditioned-based maintenance is usually most
10
20
Random Failure
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COLLEGE OF ENVIRONMENTAL DESIGN

effective because it almost always can warn a

Failure Frequency
Failure Frequency

15

Worst New
failure before it occurs 10
(Most Likely)
5

™ The warning may be subtle and give little time to 5

react. However, it’s obvious of opportunity to 0

0 1 2 3 4 5 6 7 8 9 10 11 12
0
0 4 5 6
intervene without affecting equipment greatly Period
Period
120

™ Key equipment with components that fail in a 110

progressive manner, rather than without 100 Normal Operating Range

Parameter %

90
warning, are good candidates for condition Typical Failure 80
Outside Range
monitoring 70

60 Functional Failure
™ In the other hand, components with electronic 50
0 4 5 6
circuits do not help as they fail suddenly Period

15 Condition Monitoring 16

CONDITIONED MAINTENANCE - 3/5 CONDITION – BASED MAINTENANCE - 4/5

™ Selecting the most appropriate method or ™ Some of practical monitoring methods are:
COLLEGE OF ENVIRONMENTAL DESIGN

COLLEGE OF ENVIRONMENTAL DESIGN

measurement depends on several factors: ƒ Vibration

ƒ The failure mechanism it self
ƒ The reliability of the method chosen
ƒ The warning time it gives
ƒ The cost, both initial and ongoing
ƒ The skill level required to monitor and interpret
the measure
™ To have an easy time managing cost and skill level
whenever two or three methods are used to monitor
critical component of important equipment
™ Most small to medium-sized business concentrate on
fluid and wear particle monitoring method.
ƒ Lubricants
ƒ Temperature
™ Condition monitoring is cost-effective. Depending on
the method, it can be done by a semiskilled operator
and often indicates both equipment condition and
product quality. The equipment operator using the
five senses is, therefore, the most versatile and
valuable condition monitor
™ There are more than 50 condition-monitoring and
none destructive testing techniques
17 18

3
 MONITORING METHODS - 5/5 MONITORING METHODS - 5/5
™ Vibration ™ Temperature
COLLEGE OF ENVIRONMENTAL DESIGN

COLLEGE OF ENVIRONMENTAL DESIGN

ƒ Vibration analysis monitors the mechanical movement ƒ Thermography is useful when it can be related to the
of a machine. The vibration signal is also used to condition of the equipment
diagnose the location of the problem
ƒ Problems such as loose connections, deteriorated
ƒ The most common vibration sources are misalignment
and imbalance. Problems defining involve the splices or cracked insulators are detected by
amplitude (how much movement), frequency (how temperature rises of between 10 and 100 C
fast), and phase (how much movement)
™ Lubricants
ƒ Lubricants analysis ( tribology) involves lubrication oil
condition and wear particle count
ƒ Physical and chemical analysis of the oil are
periodically compared to a baseline to check for
deterioration
ƒ The shape and size of the wear particle as well as
chemical analysis can indicate the suitability of the oil 19 20

PREVENTIVE MAINTENANCE - 1/2 PREVENTIVE MAINTENANCE – 2/2

™ PM can reduce failures and emergency repairs. It
™ For those that are not, condition monitoring
COLLEGE OF ENVIRONMENTAL DESIGN

COLLEGE OF ENVIRONMENTAL DESIGN

promotes equipment awareness and disciplined

should be carried out. For those that are age-
inspection
related:
™ It also works well for simple components that ƒ Set a standard condition, range of function
become less reliable as they age . In these
ƒ Prepare inspection, overhaul, change out, and
cases, failures can be reduced by a logical adjustment routine and schedules
overhaul or replacement schedule
ƒ Establish recordkeeping, histories, and trading
™ The first step in developing PM is to classify statistics
equipment and key component by failure ƒ Organize for analysis and periodic updating,
pattern. They are either age-related or they’r not based on the results of the routines and
schedules

21 22

COST OF TACTICS - 1/5 COST OF TACTICS - 2/5

™ It almost irrelevant to discuss the cost of ™ At some point, there is a balance between the cost
COLLEGE OF ENVIRONMENTAL DESIGN

COLLEGE OF ENVIRONMENTAL DESIGN

maintenance without considering what are buying of emergency and PM

™ The job of maintenance is to keep equipment ™ The figure assumes that proactive maintenance is
running and to enhance its speed, reliability, and indeed appropriate and effective at reducing
precision, If it is done on reactive way, after unexpected failures
Cost of emergency
breakdown occur, downtime and subsequences downtime Cost of proactive
Total cost of maintenance maintenance
repair bills will be high
™ Using PM, unexpected failure declines, as do the
Cost of proactive maintenance
production losses it causes
Cost

downtime

™ A PM approach means more and more shutdown to

inspect, adjust, overhaul, replace, and test. These
Cost of emergency
delays can cost in lost production time, At same maintenance

time, emergency repairs will taper off dramatically 23 Maintenance Effort

Maintenance Total Cost 24

4
 COST OF TACTICS - 3/5

™ To truly be prepared; experience, proper data

COLLEGE OF ENVIRONMENTAL DESIGN

COLLEGE OF ENVIRONMENTAL DESIGN

collection and analysis, and combination of good
engineering and teamwork
™ With all of that the maintenance curve could be
decrease

Thank You
Cost

Maintenance Effort
Maintenance Total Cost 25 26