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Predictive Maintenance Program

The document discusses Computerized Maintenance Management Systems (CMMS), which are software packages that help organizations better manage their maintenance operations and assets. A typical CMMS allows organizations to schedule work orders, track preventative maintenance and machine breakdowns, manage inventories, and analyze asset maintenance costs and performance. More advanced CMMS packages incorporate condition-based and predictive maintenance techniques that use data monitoring to predict equipment failures and schedule maintenance accordingly.

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28 views

Predictive Maintenance Program

The document discusses Computerized Maintenance Management Systems (CMMS), which are software packages that help organizations better manage their maintenance operations and assets. A typical CMMS allows organizations to schedule work orders, track preventative maintenance and machine breakdowns, manage inventories, and analyze asset maintenance costs and performance. More advanced CMMS packages incorporate condition-based and predictive maintenance techniques that use data monitoring to predict equipment failures and schedule maintenance accordingly.

Uploaded by

m_alodat6144
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as DOC, PDF, TXT or read online on Scribd
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Computerized Maintenance Management System

Computerized Maintenance Management System (CMMS) is also known as Enterprise Asset Management and Computerized Maintenance Management Information System (CMMIS). A CMMS software package maintains a computer database of information about an organizations maintenance operations, i.e. CMMIS - computerized maintenance management information system. This information is intended to help maintenance workers do their jobs more effectively (for example, determining which machines require maintenance and which storerooms contain the spare parts they need) and to help management make informed decisions (for example, calculating the cost of machine breakdown repair versus preventive maintenance for each machine, possibly leading to better allocation of resources). CMMS data may also be used to verify regulatory compliance. CMMS packages may be used by any organization that must perform maintenance on equipment, assets and property. Some CMMS products focus on particular industry sectors (e.g. the maintenance of vehicle fleets or health care facilities). Other products aim to be more general. CMMS packages can produce status reports and documents giving details or summaries of maintenance activities. The more sophisticated the package, the more analysis facilities are available. Many CMMS packages can be either web-based, meaning they are hosted by the company selling the product on an outside server, or LAN based, meaning that the company buying the software hosts the product on their own server. CMMS packages are closely related to Computer aided facility management packages (also called Facility Management Software). For the purposes of many organizations, the two are interchangeable. Components of a CMMS Different CMMS packages offer a wide range of capabilities and cover a correspondingly wide range of prices. A typical package deals with some or all of the following. Work orders Scheduling jobs, assigning personnel, reserving materials, recording costs, and tracking relevant information such as the cause of the problem (if any), downtime involved (if

any), and recommendations for future action. Typically, the CMMS schedules preventive maintenance automatically based on maintenance plans and/or meter readings. Different software packages use different techniques for reporting when a job should be performed.

Inspection Details condition of assets.

Preventive maintenance Keeping track of preventive maintenance jobs, including step-by-step instructions or check-lists, lists of materials required, and other pertinent details.

Machine breakdown Incidence of machine breakdown, details of repairs completed and repairs "to do". Preventive maintenance tasks are often undertaken during breakdown repair and so preventive maintenance tasks need to be rescheduled.

Asset management Recording data about equipment and property including maintenance activities, specifications, purchase date, expected lifetime, warranty information, service contracts, service history, spare parts and anything else that might be of help to management or maintenance workers. The CMMS may also generate metrics such as the Facility Condition Index (FCI) to measure effectiveness of asset management. Inventory control Management of spare parts, tools, and other materials including the reservation of materials for particular jobs, recording where materials are stored, determining when more materials should be purchased, tracking shipment receipts, and taking inventory. Safety Management of permits and other documentation required for the processing of safety requirements. These safety requirements can include lockout-tagout, confined space, foreign material exclusion (FME), electrical safety, and others. System integration CMMS packages often link to enterprise software and process control systems:

Scheduling Fixed assets Details the machines being maintained and their associated tooling Parts inventory / Parts locations / purchasing Costing SCADA Scheduled maintenance based on number of units of output or condition of machines

Condition-based maintenance (CBM) A trend in the world of CMMS is the increasing sophistication of condition-based maintenance (CBM) features and functions vendors offer and maintenance professionals actually use. CBM, a form of proactive, preventive or predictive maintenance, can be defined simply as maintenance initiated on the basis of an assets condition. Physical properties or trends are monitored on a periodic or continuous basis for attributes such as vibration, sound, temperature, particulates in the oil, wear and so on. CBM is an alternative to failure-based maintenance initiated when assets break down, and use-based maintenance triggered by time or meter readings.[1]

Predictive Maintenance Program


There are three classifications of machinery maintenance methods: Breakdown, Preventative, and Predictive Maintenance. Each method has its own associated costs and benefits. Reactive/Breakdown Maintenance, by its own nature, is the most expensive method of plant maintenance. This method has no scheduled maintenance until a machine destroys itself, and it must be replaced at great cost. The machine breakdown often brings the production process to an immediate halt. Breakdown Maintenance has high costs in manpower, replacement parts, and lost production. Preventative Maintenance, the next logical method, relies on a periodic inspection the machines. During the inspection, machine damage is found and corrected. This method requires a large inventory of replacement parts prior to the machine's inspection. Preventative Maintenance has a lower associated cost because manpower can be planned in advance. Predictive Maintenance involves monitoring the items characteristics or symptoms to diagnose its condition. This method relies on the machine's condition to accurately schedule the repair interval. The machine's condition also determines the required replacement parts. Predictive Maintenance has the lowest cost of the three methods with the highest possible savings.

Predictive maintenance (PdM) techniques help determine the condition of in-service equipment in order to predict when maintenance should be performed. This approach offers cost savings over routine or time-based preventive maintenance because tasks are performed only when warranted. The ultimate goal of PdM is to perform maintenance at a scheduled point in time when the maintenance activity is most cost effective and before the equipment loses optimum performance. This is in contrast to time and/or operation count based maintenance where a piece of equipment gets maintained whether it needs it or not.

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