What Are The Types Of Maintenance?

As far as I am concerned terminology is not important. Other than making

sure we are talking about the same thing. If what I consider to be condition-
based maintenance you call predictive maintenance that doesn’t really
matter. As long as we can sensibly talk about the underlying principles.

When to use condition-based maintenance. And how to use it.

However, as I’m often asked questions about the different types of

maintenance I decided to put a quick overview together of the types of
maintenance. At least, the way I see it:

There are 9 Types of Maintenance split between Preventive Maintenance and

Corrective Maintenance. 

Preventive Maintenance is done before a failure occurs and consists of

maintenance types like: Time Based Maintenance, Failure Finding
Maintenance, Risk Based Maintenance, Condition Based Maintenance and
Predictive Maintenance. 

Corrective maintenance is done after a failure has occurred either as Deferred

Corrective Maintenance or as Emergency Maintenance.

In the rest of this article, I will discuss each of these different types of
maintenance in detail:

Preventive Maintenance (PM)

 Time Based Maintenance (TBM)

 Failure Finding Maintenance (FFM)
 Risk Based Maintenance (RBM)
 Condition Based Maintenance (CBM)
 Predictive Maintenance (PDM)

Corrective Maintenance (CM)

 Deferred Corrective Maintenance

 Emergency Maintenance (EM)

Preventive Maintenance Vs Corrective

Maintenance
At the top level, I see maintenance being either preventive or corrective:

 When we do preventive maintenance we are doing a task before a

failure has occurred. That task can be aimed at preventing a failure,
minimising the consequence of the failure or assessing the risk of the
failure occurring.
 When we are conducting corrective maintenance the failure has now
occurred and we are basically reinstating equipment functionality. To
be clear, corrective maintenance can be the result of a deliberate run-to-
failure strategy.
Preventive Maintenance (PM)
Preventive maintenance can be defined as “an equipment maintenance
strategy based on replacing, or restoring, an asset at a fixed interval
regardless of its condition. Scheduled restoration tasks and replacement tasks
are examples of preventive maintenance tasks.” 1

Preventive maintenance (or preventative maintenance) is basically a type of

maintenance that is done at a regular interval while the equipment is still
functioning with the objective of preventing failure or reducing the likelihood of
failure.

Preventive maintenance can be time based i.e. every week, every month or
every three months. But preventive maintenance can also be based on usage
e.g. every 150 cycles, every 10,000hrs or like your car: service every
10,000km.

Apart from the regular interval approach (time based maintenance) there are
also other types of maintenance that fall within the category of preventive
maintenance:

 Time Based Maintenance (TBM)

 Failure Finding Maintenance (FFM)
 Risk Based Maintenance (RBM)
 Condition Based Maintenance (CBM)
 Predictive Maintenance (PDM)

In the following paragraphs, I will explore each of these types of maintenance

in more detail including when you should consider using them.
Time-Based Maintenance (TBM)
Time-Based Maintenance refers to replacing or renewing an item to restore its
reliability at a fixed time, interval or usage regardless of its condition. This is
what Moubray calls Scheduled Restoration or Scheduled Discard tasks in
his RCMII book.

I limit the use of that phrase as for some reason people then jump to the
conclusion that another maintenance is not scheduled. When in fact, of
course, all maintenance should be scheduled through our Weekly Schedule.
The only exception would be Emergency Maintenance, which due to its very
nature of requiring immediate attention cannot be scheduled.

The purpose of Time Based Maintenance is to protect yourself against

the failure of known wearing parts which have predictable Mean Time
Between Failure (MTBF) i.e. Time Based Maintenance assumes that the
failure is age related and a clear service life can be determined. Or, that it’s
simply not worth the effort to assess the condition and a time based
replacement is more economical and still (reasonably) effective.

Time Based Maintenance can never effectively manage non-age

related failure modes and therefore should only form a small part of your
overall maintenance program as >70% of the failure modes in your plant are
not age related (refer to the article 9 Principles of Modern Maintenance).

It is important to realise that in many industries companies do have to

complete certain tasks to meet regulatory compliance requirements and these
would typically be executed on a fixed time interval i.e. Time Based
Maintenance. But even with compliance related maintenance, there are often
opportunities to engage a regulator and look at moving to for example risk-
based approaches. A good example of this would be adopting Risk-Based
Inspection (RBI) for vessel inspections instead of e.g. 4-yearly internal vessel
inspections.

Failure Finding Maintenance (FFM)

Failure Finding Maintenance tasks are aimed at detecting hidden failures
typically associated with protective functions. Think pressure safety valves,
trip transmitters and the like.
This type of equipment won’t be required to function until something else has
failed. That means that under normal operating conditions you will not know
whether this equipment is still functional i.e. the failure modes are hidden.

And since these failures are hidden, you’ll need to find them before you are
relying on that equipment to protect you.

Simple really.

It’s important to realise that failure finding maintenance tasks do not prevent
failure but simply detect it. And once detected you’ll have to repair the failure
you found. Failure Finding Maintenance is conducted at fixed time intervals
typically derived from legislation or risk based approaches.

Risk Based Maintenance (RBM)

Risk Based Maintenance (RBM) is when you use a risk assessment
methodology to assign your scarce maintenance resources to those assets
that carry the most risk in case of a failure (remembering that risk = likelihood
x consequence).

As a result, equipment that has a higher risk and a very high conseauence of
failure would be subject to more frequent maintenance and inspection. Low
risk equipment may be maintained at a much lower frequency and possibly
with a much smaller scope of work.

When you implement a Risk Based Maintenance process effectively you

should have reduced the total risk of failure across your plant in the most
economical way.

Risk-Based Maintenance is essentially preventive maintenance where the

frequency and scope of the maintenance activities is continuously optimised
based on the findings from testing or inspection and a thorough risk
assessment. Examples of Risk-Based Maintenance would be Risk-Based
Inspection as applied to static equipment like vessels and piping or even
pressure relief valves.
Condition Based Maintenance (CBM)
Most failure modes are not age related. However, most failure modes do give
some sort of warning that they are in the process of occurring or are about to
occur.

If evidence can be found that something is in the early stages of failure, it may
be possible to take action to prevent it from failing completely and/or to avoid
the consequences of failure. Condition Based Maintenance as a strategy
therefore looks for physical evidence that a failure is occurring or is about to
occur. Thinking of CBM in this way shows its broader applications outside
condition monitoring techniques often only associated with rotating equipment.

Predictive Maintenance (PDM)

Up until recently when people spoke about Predictive Maintenance (PDM) this
was essentially as a synonym for Condition Based Maintenance. But with the
advent of Artificial Intelligence, much lower costs of equipment sensors (IIoT)
and machine learning there is clearly a difference appearing between
Predictive Maintenance (PDM) and Condition Based Maintenance (CBM), at
least in my view.

I see Predictive Maintenance as an extension, a more advanced approach to

CBM where we use potentially many process parameters gained from online
sensors to determine if our equipment is moving away from stable operating
conditions and is heading towards failure. The central idea here is to predict
when the failure is going to occur and then determine the appropriate time for
maintenance intervention.

There are a lot of (very large) companies actively moving into this space and it
is certainly a fast-moving and exciting part of our discipline as Maintenance &
Reliability professionals. However, I do still believe that even the most
advanced Predictive Maintenance approaches need to be underpinned
by sound reliability principles and understanding. And I also believe that the
use of Predictive Maintenance  

Corrective Maintenance (CM)

A Run to Failure or Corrective Maintenance strategy only restores the function
of an item after it has been allowed to fail. It is based on the assumption that
the failure is acceptable (i.e. no significant impact on safety or the
environment) and preventing failure is either not economical or not possible.

Apart from being the outcome of a deliberate Run to Failure

strategy Corrective Maintenance is also the result of unplanned failures which
were not avoided through preventive maintenance.

A run to failure strategy can effectively be used for general area lighting, smart
process instrumentation (without trip functionality) etc. where the
consequence of failure is limited and would not necessitate a need for an
urgent repair.
When opting for corrective maintenance as a strategy it is essential to ensure
that the failure modes under consideration do not have the potential to
become Emergency Maintenance. You see, if you adopt run-to-failure for
equipment that once it has failed must be restored immediately to have
doomed your organisation to a reactive maintenance environment. A reactive
maintenance environment is not where you want to be. It is more expensive,
less efficient, and less safe.

So although a run-to-failure strategy can be a good option, make sure you

decide wisely.

Deferred Corrective Maintenance

In the chart of maintenance types I broke ‘corrective maintenance’ into two
sub-types:

 Deferred Corrective Maintenance

 Emergency Maintenance (EM)

And that was very deliberate because it is so essential that we absolutely

minimize the amount of Emergency Maintenance we allow into our
organisations. As I already pointed out above Emergency Maintenance is
expensive, various sources have suggested that Emergency Maintenance is 3
to 5 times as expensive as ‘normal’ preventive maintenance. Emergency
Maintenance typically leads to longer equipment outages and more production
impact. And it is less safe. So when a corrective maintenance work request is
raised it is essential that you prioritise it properly to make sure that where
possible you defer the work request and give your team the time to properly
plan and schedule the work.

If you want to read more about prioritisation of corrective maintenance have a

look at the article You Will Fail Without Planning & Scheduling.

Emergency Maintenance (EM)

Emergency Maintenance is corrective maintenance that is so urgent that it
breaks into your Frozen Weekly Schedule (you do have one don’t you?).

It upsets your plans and schedules and typically throws everything into
disarray.

Some people thrive in this type of environment and often get heralded as
heroes when they’ve worked 16hrs non-stop to get production back online.
But when it comes to the Road to Reliability it is a dead end.

So Emergency Maintenance is the one and only maintenance type that we

really want to avoid as much as possible. In fact, World Class organisations
ensure that less than 2% of their total maintenance is Emergency
Maintenance.

How much Emergency Maintenance do you have?

LOTOTO PROCEDURE

LOTOTO, also referred to as "Lock-Out Tag-Out Try-Out", is a safety procedure used in

industry to ensure that hazardous machinery/situations is properly locked before starting
maintenance.

LOTOTO is a method in which a situation is made safe by locking area’s or turning off
switches and test if the lockings work properly etc. This will be done in such a way that
other persons cannot undo this protection. Usually special padlocks are used for this. At the
same time, where necessary, labels (Tag) are applied, showing that for instance, the
machine is under maintenance, but also showing who is working on it. An important aspect
of LOTOTO is that all employees involved become aware and remain aware of the
necessity to work according to the safe (LOTOTO) method.
 

Permit to Work and LOTOTO

WPS has a fully equipped LOTOTO system that can run on its own or in combination with
the work permit system. This way, when using LOTOTO in combination with work permits,
safety levels rise because the WPS system first demands all the necessary lock-outs before
providing/releasing the work permit.