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Maintenance management system

Article in MM Science Journal · September 2015

DOI: 10.17973/MMSJ.2015_10_201532

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Hana Pacaiova Juraj Glatz

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 MAINTENANCE Process is defined as a set of activities using resources and
regulations to enable the transformation of inputs into outputs.
MANAGEMENT SYSTEM The process approach represents identification, interaction and
process control in such way that the output of one process is
HANA PACAIOVA, JURAJ GLATZ presented as input to the next process. This relation can be
understood as the certain interconnection of process Nenadal
Technical university of Kosice, Safety and Quality
et al. 2008, Popovic 2010.
Production Department, Kosice, Slovakia
Continual improvement of the organization’s performance
needs to be taken as a major goal of any kind of organization!
DOI: 10.17973/MMSJ.2015_10_201532
e-mail: [email protected] 2.1 Maintenance Management & Systematic Approach
Maintenance terminology EN 13306, 2001 understands
Maintenance Management requires acceptance of basic maintenance as a process which includes management,
systems approach, i.e. implementation of company goals to administrative and technical activities in order to maintain or
management goals. Well know Maintenance management restore equipment into the required state. In the introduction
philosophies (TPM, RCM, RBI) applied in order to improve requirements on safe and quality maintenance are pointed out.
processes, often remain only on the basis of the Into account are also taken requirements on control of
implementation of services without the need for full integration environmental impacts and costs effectiveness.
into existing management systems. In some literatures Pacaiova et al. 2011, Dhillon 2008 states,
Misunderstanding the nature of maintenance management that maintenance costs are in range from 20% to 35% of
leads to inefficient step, resulting in a contradiction between production costs. More than 25% of accidents in underground
the goals of management and their ability to support real goals mines happen during maintenance. More than 10% of loss of
through maintenance management. production time happens due to corrective maintenance, etc.
Process approach in the management of maintenance is the Each of these indicators appeals to "backlog" (reserves), which
basis for improvement in maintenance and hence achieving the results not only from the so-called: direct maintenance costs
required performance. but mainly from so-called: induced costs, which result from
This article, based on practical experience, analyzes the root deficiency of maintenance planning.
errors caused by maintenance management in order to apply It is important that maintenance management is aware of not
the selected philosophy in the management of maintenance only the principles of system`s management, but also the tools
without the knowledge or lack of willingness to accept a and sources for strategy decision and maintenance activities
systemic approach to maintenance management. based on analytical approaches and methods, such as:

KEYWORDS  Root Cause Analysis (RCA)

risk management, TPM, RCM, FMEA, KPI  Failure Modes and Effects Analysis (FMEA/FMECA –
Criticality Analysis)
1 INTRODUCTION  Fault Tree Analysis (FTA)
In industrial practice the basic effort is to reduce costs and  Hazard and Operability Analysis (HAZOP)
increase profits. Often it happens by the changes, respectively  Human Error / Reliability Analysis (HEA/HRA).
manufacturing processes innovation. But we always talk about
technological processes, which effort is to reduce their energy Certain methods are indicated as standard analytical methods
consumption, while taking into consideration the entire life and are usually accompanied by the criticality analysis, i.e.
cycle of technology systems, as well as selection of suitable analysis of critical equipment which criteria correspondent to
maintenance strategy in order to minimize losses and waste. those areas where management of the company points out
Maintenance as combination of all technical, administrative steps by its policy or through company goals (sources and
and management activities during the object´s life cycle in responsibility). In these areas will be used precautions to
order to maintain or restore it to a state where it can perform prevent unwanted - uncontrolled loss (safety, environment,
required function, has an impact on safety, environment, quality, information safety, cost, etc.).
product quality, total profit, respectively loss of company. As Maintenance strategies (see Fig. 1) are therefore focused on
follows from the definition of EN 13 306, 2001, maintenance prevention of the failure mode, where failure of equipment has
is not only the task of ordinary employees working on the its "critical" impact on desirable results (goals) or at a
maintenance position, but it is mainly management role into "tolerable" risk is a maintenance strategy focused on repair in
which it is necessary to include each employee of the company. case of failure occurs Pacaiova et. al 2009.
Different management philosophies help to monitor targets
companies, often with the support of specific management
systems (quality, environment, safety, information safety). It
often happens that these systems do not correspond with the
goals of maintenance management and have little or even
controversial impact on its management.

2 BASE PRINCIPLE OF SYSTEMATIC APPROACH IN

MAINTENANCE
Management system is a set of interconnect processes that
brings to the organization increased efficiency and
effectiveness in achieving determined objectives.

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 support (maintenance support) for the implementation of
MAINTENANCE STRATEGY
planned activities based on the specified management goals
(Maintenance Task Analysis, Criticality Analysis).
before breakdowns/failure after breakdowns/failure Nowadays in the maintenance management are well known
mainly the following philosophies, which are completely or with
Scheduled/planned Predictive Corrective
minor editing suitable for most industrial companies, as
described in Tab. 1:
Function Monitoring and Immediate Deferred  TPM – Total Productive Maintenance developed in Japan as
tests inspection maintenance maintenance
a conception of maintenance management including all
departments, i.e. from management to manufactory,
If not If not
enough enough controlling support of company’s maximum productivity
based on increase principle of production equipments
Tasks: lubrication, cleaning, calibration, renovation, reparation, replacement, effectiveness. Author of the TPM conception is Seichi
adjustment ...
Nakajima, who gradually studied systems for preventive
maintenance in 50tees a 60tees years (Preventive
Maintenance) in the USA a Europe Rakyta 2010.
Figure 1. Maintenance strategy and maintenance tasks  RCM – Reliability Centered Maintenance presents
systematic approach for identification of effective and
We know two basic maintenance strategies: preventive equipments and their elements maintenance
 preventive - focused on prevent of failures activities according to specific procedures and proceedings
 corrective - focused on efficient repair of equipment after based on intervals defined to perform single maintenance
the failure occurrence. activities. It was developed when maintaining planes of
Preventive strategy in a simplified context may be scheduled Boeing 747 a 777 type in the USA and in 1960 - 1970 it was
"fixed" by time, mileage, cycles, etc., or may be performed officially elaborated as a base for maintenance
when "monitoring state" of equipment would lead to an management mainly in aircraft industry (technical standard
accident (we call it predictive maintenance strategy). SAE JA1011).
Criteria of choosing the maintenance strategy in the planning  RBI – Risk Based Inspection is an assessment and risk
phase are specified areas of seriousness losses, as a result of management process, which evaluates loss risk of pressure
failure – i.e. loss of equipment function, and may be threat of equipment’s content influenced by materials deterioration.
set goals of the company. It is mainly in areas of: This risk is controlled by equipment’s inspection. That
 safety of company employees, means that the priorities of maintenance activities are
 public safety close to company surroundings, defined according to analyses and risk assessment.
 threat of environmental requirements,  RIMAP - Risk Based Inspection and Maintenance
 loss of production quality or delivery delay , Procedures is a result of European project (5 framing
 loss of company property or foreign ownership, project EU 1998-2002), which goal was to develop unitized
 the high costs spent on equipment repair in case of failure, optimal approach to inspection and maintenance activities
 losses affecting the region's economy or economy of all based on risks assessment in industrial companies).
society.
Nowadays in companies we can also often find criteria such as RCM TPM RBI
“loss of company image” as a result of major industrial USED IN Design, Design,
Operation and
accidents. PHASE OF Operation and Operation and
Maintenance
Assurance of the company goals is possible only if there are LIFE CYCLE maintenance maintenance
provided sources and support from company management, so MAIN USED Chemical, Automotive, Chemical,
that these goals could be transformed into maintenance IN petrochemical, brewing, food, petrochemical,
management goals, see Fig. 2. INDUSTRY gas, nuclear manufacturing gas, nuclear
CRITICALITY
ABC* ABC ABC
FILTER
COMPANY POLICY AND OBJECTIVES Max. Health, safety
Max. reliability
OBJECTIVE effectiveness and
and safety
Maintenance and availability environment
Outputs
support - Production FTA, ETA,
- Staff requirements FMEA,
- Spare parts METHODS OEE*, P-M* social risk
Maintenance - Requirements Ishikawa
- Tools and
policy and for quality and assessment
equipment productivity,
- Information objectives
- Cost
*ABC - equipment categories – A, B, C, OEE – Overall Equipment
and their - Image Effectiveness, P-M – Analysis
security

Table 1. Examples of Maintenance philosophy application

Other factors: Lifetime of Level and culture
- Energy business and of safety
- Position of equipment
company
3 FROM MAINTENANCE MANAGEMENT TO ASSET
MANAGEMENT
In the area of machinery safety and other technical systems,
Figure 2. Factors influencing of maintenance goals according to the Directive 2006/42/EC, there is clearly
formulated requirement of integration of safety aspects into
design phase of machinery (not excluding the whole life cycle),
2.2 Maintenance Philosophies
with respect to given goals of a company. This principle is base
Planning in maintenance management requires the application
philosophy in company´s physical assets management strategy,
of such analytical methods which are able to ensure adequate

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which requires implementation of process tools at all In a company it is important to identify possible areas of losses,
management levels. which might have influence on given corporate objectives. It is
Integrated care for assets, Asset Management (AM) is focused possible to specify them, e.g. in a production company, as
on optimum management of assets life cycle so that all follows:
strategic objectives of an owner are fulfilled – either physical  equipment effectiveness
body or company Hladik, 2013, Grencik 2013, Snah and  personnel effectiveness
Littlefield, 2009.  resources consumption effectiveness
According to the EFNMS (European Federation of National  safety level
Maintenance Societies), AM is based on systematic and  production quality level
coordinated decision making, actions and procedure by which  environmental protection level
the organisation:  legislative requirements conformity
 identifies potential strategic physical assets,  corporate image.
 successfully manages especially their performance, risks Another approach to risk management is the standard from the
and costs during the whole life cycle, year 2002, which has been a result of work of the Committee of
and this with the objective to achieve the strategic goals of the Sponsoring Organizations of the Treadway Commission (COMO,
organisation. USA), objective of which was to prevent scandals on markets
concluding from insufficiently assessed risks. This committee
created integrated approach to risk management to support
3.1 Relation between Asset management and Maintenance businesses and other entities assess and enhance their internal
In the publication Legat et al. 2013, physical asset control systems.
management, as it was understood in the past, has been It defines: ”Enterprise risk management (ERM) is a process,
defined as a program of its acquisition, utilisation and effected by entity´s board of directors, management and other
maintenance, based on set of rules, methods, procedures and personnel, applied in strategy setting and across the enterprise,
tools for optimising of effects of costs, performance and risks designed to identify potential event that may affect the entity
during its life cycle, see Fig. 3. and manage risk to be within its risk appetite, to provide
Although the term of risk is mentioned in this definition, its reasonable assurances regarding the achievement of entity
relation to corporate objectives is not clearly specified. Usually objectives.
the term of risk has been associated with the occupational AM is based on these principles of integrated management, as
health and safety (OH&S) area. it is given in ISO 31000 or in ERM. First of all it requires the
identification of strategic physical assets, that is those, which
are important for given corporate objectives, on the other hand
assessment their risks, that is an analysis and management of
Corporate Asset Maintenance factors and conditions affecting these strategic physical assets
management management management in achieving required objective during the whole life cycle of
the assets.

3.3 Tool for Risk assessment in AM frame

Figure 3. Hierarchy of management processes
In general, the principle of risk management comprises
respecting the following fundamental steps:
On the other hand the definition of corporate management
a) Risk analysis and Risk assessment
Legat et al. 2013 specifies “the process of leading,
 Determination of the object boundaries
administrating and directing a company. Business tasks often
 Identification of threats and hazards, determination of
performed by corporate management might include strategic
likelihood and consequences.
planning, as well as managing company resources and applying
them toward attaining the company's objectives”.  Risk estimation as a combination of Probability (P) and
In the past, reliability was understood as one of quality Consequences (C)
parameters of a product / item. b) Risk evaluation
In several publications and presentations Legat at al. 2013,  Risk assessment (acceptability, tolerability)
c) Risk control.
Fangucci and Caltanissetta 2010, Nenadal 2010 it is pointed at
Establishment of measures, i.e. determination of barriers
the fact that very often has been neglected, while is decisive,
according to legislative requirements and internal regulations
implementation of dependability management (reliability,
(e.g. ALARP system = As Low As Reasonably Practicable),
maintainability, maintenance supportability and other
requirements) as part of sub-implementation phases. Lauwers 2010.
Dependability management in broader understanding is The selection of suitable methodology for risk assessment and
important – specific part of quality management system which control is based on:
is inseparable component of corporate management.  Effectiveness and simplicity of algorithm
 Extent covering the scope and required functions of
assessed system/operations
3.2 Asset management and Risk management
 Comprehensibility
Standard 31000 has changed the definition of risk from “the
 Transparent accessibility of conclusions
chance of something happening that will have an impact on
 Feedback possibility.
objectives” to “the effect of uncertainty on objectives”.
In case of AM the process of risk management can be describe
While managers will continue to consider only the risk
as follow:
evaluation and risk managers to consider the possibility of risks
a) Risk analysis and Risk assessment;
occurring, they should now apply risk treatment options to
 Determination of the object boundaries – plant,
ensure that the uncertainty of their agency meeting its
technology, equipment
objectives will be avoided, minimized or removed.

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 Identification of threats and hazards, determination of complex of hazards is nowadays becoming, as from external as
likelihood and effects state on objectives well from internal environment, a recognised factor available
 Risk estimation as a combination of Probability (P) and for public. Requirements on safety for protection of life and
Objective Effects (E) health of personnel have been transferred on the external
b) Risk evaluation environment in which a company is performing and there is
 Risk assessment (acceptability, tolerability) even pressure increasing on co-responsibility of corporate
c) Risk control – through integrated effective and efficiency managers overlapping frames of a country or state in which the
measures. company is performing (Directive 2008/114/EC).
The Risk management process can be presented as a list of This important aspect brought by ISO 31000 needs creation of
coordinated activities, represented by 7Rs and 4Ts: suitable methodology that could by certain unified manner help
 Recognition or identification of risks the asset management to assess in the most objective way
 Ranking or evaluation of risks their activities in relation to given objectives, so that the
 Responding to significant risks decision making and control of measures was economically
effective and morally acceptable for all interested parties.
 Tolerabe (To)
Planning maintenance strategies and performance of
 Treat (Tr) maintenance activities can bring required effect only if it is
 Transfer (Tf) based on system tools and tools assigned for risks assessment
 Terminate (Te) of run and maintained technical equipment. Dynamic
 Resourcing control maintenance program must takes into account any operation
 Reaction planning changes and equipment conditions that are part of risk analysis
 Reporting and monitoring risk performance and its goal must be process of continual improvement.
 Reviewing the risk management framework.
The following table describes proposal of possible methods for ACKNOWLEDGEMENTS
implementation of ISO 31000 principles into AM. This paper is the result of the implementation of project KEGA
No. 049TUKE-4/2014 “Designing a Model for E-learning Support
Lifecycle Requirements RM of the Education in the Production Quality Bachelor Study
phase tools Program”.
Concept, Formulation of requirements on What if?
Intention equipment – in relation to Effects REFERENCES
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CONTACTS
prof. Ing. Hana Pacaiova, PhD.
Technical university of Kosice, Faculty of Mechanical engineering, Safety and Quality Production Department
Letna 9, Kosice, 04011, Slovakia
+421903710474, e-mail, [email protected]

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