Maintenance Engineering &

Management

Lect. 1 - Introduction

By

Prof. P.N. Muchiri

 I. Setting the scene

Maintenance Management
Defined

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 Overview
• Definition.
• Context.
• Historical perspective.
• Critical success factors.

• Course overview.

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 Definition
• In theory …
– The maintenance of the means of “production” can be defined
as “the set of activities required to keep these means of
production in the desired operating condition, or to restore them
to this condition”.

– The objective of maintenance management - total asset life

cycle optimization - can therefore be defined as the maximizing
of the availability and reliability of the means of production with a
view to producing the desired quantity of products to the required
quality specifications.
This objective must evidently be realised in a cost-effective
manner and in accordance with environmental and safety
regulations.
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– Evolution in terminology:
Maintenance management  Enterprise asset management

(SAMI, 2009)

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– Link: Roles in asset management

Asset owner

Asset manager

Asset operator

Asset builder Service provider

(The Institute of Asset Management, 2007)

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• In practice …
Maintenance management is
This ? Yes ... But also a lot more !!

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• Example: Automotive industry
– Manufacturing Automated lines
• Metal forming
Heavy machinery Hand tools
• Welding
• Painting Calibrated equipment Robots
• Assembling
Dustfree rooms
• Testing Fixtures
• … Transportation equipment

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– Maintenance
• Jobs: Repairing failed machines, Replacing worn-out parts,
Cleaning, Inspecting, Monitoring, Measuring, Calibrating,
Diagnosing problems, Supporing Engineering, …
• Fields: Mechanics, Electronics, Instruments, Hydraulics, …
• Skills: Hands-on, Analysis, Engineering, Planning, …

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– Example: Chemical plant

600 ha, 53 plants

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Predictive techniques Application examples
Vibration measurement Used for checking
• roller bearings in pumps and compressors
• sleeve bearings in turbines
• 3D structures like vessels
Ultra sound measurement To detect leakages
Oil analysis To detect metal particles and oxidation particles
Infrared measurement To check switch boxes, insulation and heat exchangers

90,0°

80
C

60

40

20
20,0°

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– Example: Distribution center

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– Example: Hospital

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• Related terminology
• Repair
• Replace
• Refurbish
• Retrofit
• Restore
• Recondition
• Renovate
• Remanufacture
• Rebuild
• Recycle
• Reuse

Note: Exact definitions may differ slightly from source to source.

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• Repair: minor fixing, ABAO
• Replace: part change, AGAN
• Refurbish: existing components are renovated or replaced with components of similar design; this
will overcome plant degradation and lifetime problems but will not provide increased performance.
• Retrofit: Principally retrofitting describes the measures taken in the manufacturing industry to
allow new or updated parts to be fitted to old or outdated assemblies. The production of retrofit
parts is necessary in manufacture when the design of a large assembly is changed or revised.
• Renovation is the process of restoring or improving a structure.
• Recondition: To restore to good condition, especially by repairing, renovating, or rebuilding.
Often used for major undertakings (changes)
• Remanufacturing is the process of disassembly and recovery at the module level and,
eventually, at the component level. It requires the repair or replacement of worn out or obsolete
components and modules. Parts subject to degradation affecting the performance or the expected
life of the whole are replaced. Remanufacturing differs from other recovery processes in its
completeness: a remanufactured machine should match the same customer expectation as new
machines. (with or without identity loss)
• Rebuild: old name for remanufacturing
• Reuse is using an item more than once. This includes conventional reuse where the item is used
again for the same function, and new-life reuse where it is used for a new function.
• Recycle: In contrast to reuse, recycling is the breaking down of the used item into raw materials
which are used to make new items.

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Definities
• Repair: failure - ABAO
• Replace: failure or precaution - AGAN
• Refurbish: similar
• Retrofit: new, better

• Restore: (AGAN), minor or major

• Recondition: major
• Renovate: major

• Remanufacture: disassembly – module level - identity

• Rebuild: disassembly – module level – identity

• Recycle: disassembly – old components for new items

• Reuse: second hand

Note: Exact definitions may differ slightly from source to source.

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(Alstom: Steam Turbine Retrofits, 2007)
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• Context

Society

Management
What and how we decide
Methods & processes
Operations
Technology
Total asset Why we do it
What it is about
life cycle Maintenance services
* Plant & installations
optimization and core production
* Tools/Shops/Cribs
activities
Logistic support
What we need
Planning, delivering, controlling
* Spares * Personnel

Competitive business context

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Exercise: What are these “contexts” for the following examples ?
– Industrial packaging machine

– Chemical plant

– Office photocopier

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Contexts Photocopier Chemical installation
Operations Office – Home Variable/fixed specifications
Continuous/batch
Management Maintenance contract Maintenance strategy
Link production-maintenance
Technology Newest or standard Process risks
Logistics Special paper Training – Maintainability
Innovation Remote monitoring Competitive technologies
User interventions Automation (control, monitoring)
Legal User safety Occupational safety
Environment (toner) Inspection schedules
Environment
Business Critical ? Critical !!
Market Number of suppliers Maintenance services
Buy instead of make
Societal (spares developing countries) 24/24 – 7/7 (shifts)
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“simple” systems ...

roads cars buildings utilities

“complex” systems

aircrafts telecom assembly line oil rig wind mill farm

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Required:

theory

analyses spare parts

inspections

technical skills

management skills

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 Historical perspective
maintenance – engineering - production –business

Changes in the playground

Installation complexity - Competitive pressure – Customer focus -
Dynamically changing business context

1940 1950 1960 1970 1980 1990 2000

Impact on maintenance management

Changing requirements and practices
Higher expectations
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 <1950 1950-1975 >1975 2000-….

industry installation complexity 

equipment life cycle  and reliability 
automation 
customer service 
competition 
maintenance insight in failures and impact of (non)maintenance 
corrective  preventive  condition based, design
maintenance concept focus 
maintenance from techniques to technical management
management technical level 
ICT support 
outsourcing 
academic interest 
necessary technical business partnerships
evil function function

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 <1950 1950-1975 >1975 2000-….

industry installation complexity 

equipment life cycle  and reliability 
automation 
customer service 
competition 
maintenance service sector 
legislation (safety, environment) 

equipment:
* not highly mechanized * fully automated
* overdesigned * right capacity
* simple * very complex
* stand-alone * integrated systems

business environment:
* cfr Henry Ford * focus on the customer
* inventory control * MRP, JIT, JIS, …BPR, …
* local business * globalisation

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 <1950 1950-1975 >1975 2000-….

maintenance insight in impact of (non)maintenance 

corrective  preventive  condition based, design
maintenance concept focus 
views on equipment failures:

CBM
CM PM ! DOM

maintenance expectations:
TPM
BCM RCM

LCC

maintenance concept focus:

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 <1950 1950-1975 >1975 2000-….

maintenance from techniques to technical management

management technical level 
ICT support 
outsourcing 
academic interest 
changing career opportunities 

Third Generation:
•Condition monitoring
•Design for reliability
& maintainability
•Small, fast computers
Second Generation: •Decision support tools
•Scheduled overhauls e.g. ES, FMEA, HAZOP,…
First Generation: •Systems for planning •Shift in organizational thinking
• Fix it when it and controlling work e.g. multiskilling, team work,
broke •Big, slow computers outsourcing

1940 1950 1960 1970 1980 1990 2000

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Stuff to think about

Maintenance
aspects Boeing 747

24 hours 97 % technical accuracy

700 hours
between “A” inspections

71 %
8 hours for job
100 hours

Time
(horizon  30 years)
Source: Storck 2004
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 1940 1950 1960 1970 1980 1990 2000

Failure based maintenance

(reactive, i.e. corrective maintenance only)

Time based maintenance

(traditional preventive maintenance)

Condition based maintenance

(predictive, i.e. opportunity for e-maintenance (prognostic)

Design-out maintenance
O&M Best Practices Guide, 2007 (maintainability & reliability issues)

Average maintenance program activities

reactive
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preventive
predictive
other
• The field “maintenance management”
• Is a young management area
• Deals with complex, automated equipment
• Involves high costs
• Sees a growing service sector
• Experiences a closing gap between academics & practice
• Enjoys a growing professionalism
• Focus now on
– competitiveness
– human factor
– ICT opportunities
– new organizational structures
– evolving maintenance concepts

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 Critical success factors
Basic + updating
Technology – Analyses
Technical and Challenges
technological equipment and business
background During career 

CSF for
Management maintenance
skills management Flexibility

People manager Dynamic, global environment

“PDCA” New (management) tools
IT savvy Organizational changes
Financial insights Evolving maintenance concepts
During career  Outsourcing markets 36