Module 03:

Introduction to Maintenance Lecture 06 (A) :

Management System in Mining Introduction to CMMS
• Introduction to Maintenance
• Types of Maintenance
• Maintenance management
• Fundamental steps of maintenance management
• Computerized maintenance management system (CMMS)
• Benefits of CMMS
• CMMS subsystem or modules
• CMMS software models

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• CMMS software
• New trends in the CMMS or enterprise asset management industry
• EAM vs. CMMS
• Introduction to Asset Performance Optimization
• Challenges in Asset Management for the Mining Sector
• Benefits of CMMS Solutions for Mining Companies
• Key Features of CMMS for the Mining Industry
• Implementing CMMS in Mining Operations
• Future Trends in CMMS for the Mining Industry

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Maintenance
Maintenance refers to the systematic and organized control of activities necessary to preserve a

facility in its original condition, ensuring it retains its productive capacity over time.

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Types of Maintenance

Corrective Preventive
maintenance maintenance

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Corrective maintenance
• Corrective maintenance is carried out reactively after a fault has been recognized. It

aims to restore the equipment in question into a state in which it can again perform a

required function.

• Depending on the maintenance plan corrective maintenance can be either planned or

unplanned.

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• Planned corrective maintenance is typically result of a run-to-failure (RTF) maintenance

plan where no maintenance is performed on the asset until the failure event.

• Unplanned corrective maintenance is typically the result of a breakdown not stopped by

preventive maintenance.

• Based on the fault and the business conditions corrective maintenance can either be

done immediately after the fault occurs or it can be delayed and performed later.

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Preventive maintenance
• Preventive maintenance is performed proactively before the equipment fails. It

intends to reduce the probability of failure or degradation of the functioning of an

item.

Predetermined maintenance

Predetermined maintenance is done based on established maintenance programs for

intervals of time or units of use. The programs are typically provided by equipment

manufacturers and are based on their knowledge of the failure mechanisms and

mean-time-to-failure (MTTF) statistics for the equipment and its parts.

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• The programs are typically provided by equipment manufacturers and are based on

their knowledge of the failure mechanisms and mean-time-to-failure (MTTF) statistics

for the equipment and its parts.

Figure-Typical bathtub curve

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• The failure probability is typically higher when the equipment or part is new or worn out.

• This MTTF or bathtub curve is shown in Figure. Predetermined maintenance does not

guarantee that the equipment does not fail and often leads to unnecessary repairs since

the programs are based on failure statistics and not on the actual condition of the

equipment.

• Managing predetermined maintenance can be complex since each equipment can have

multiple maintenance programs and companies can have a large number of equipment.

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Condition Based Maintenance

• Condition-based maintenance tries to predict failure. It is based on regular monitoring

of the condition, operating efficiency, and other indications of the system.

• The monitoring can be done either on-site or remotely via a network connection to the

equipment. Monitoring can be done continuously, or it can be scheduled to happen at

predetermined intervals.

• Condition-based maintenance is the most complex maintenance type to implement but

can be the most economical one since only the parts needing repair or replacement are

maintained.

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Question 1

How is monitoring conducted in condition-based maintenance?

a) On-site only

b) Remotely only

c) Both on-site and remotely

d) Continuously

e) Only at predetermined intervals

Answer: c) Both on-site and remotely

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Maintenance Management

Initially, maintenance management was a manual, time-consuming task. However, it has

evolved into a Computerized Maintenance Management System (CMMS), a software that

centralizes planning, tracking, measuring, and optimizing all aspects of a maintenance

program.

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Fundamental steps of maintenance management

Management
Request Approval Plan
management

Recording data Performing work Schedule

Developing
Updating
Accounting for management
equipment
costs information and
history
control reports

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Computerized maintenance management system (CMMS)
A combination of different
Used by maintenance professionals modules that combine in one
across different industries. comprehensive solution.

CMMS = Computerized Maintenance Management System

Used to plan, organize, track,

Digital solutions used on and optimize maintenance work.
a computer/mobile device,

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Computerized maintenance management system (CMMS)
A computer-managed maintenance system is an integrated set of computer programs and data

files designed to provide its user with a cost-effective means of managing massive amounts of

maintenance, inventory control, and purchasing data.

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• It helps in systematic planning, execution, and control of maintenance activities.

• It provides a cost-effective way to manage human and capital resources.

• CMMS is a transformation from a paper-based working environment to a computerized

digital storage. It helps to eliminate the recording of paperwork.

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Input and output model for an enterprise
• Figure below highlights the resources which need to be managed in an enterprise. It can

be seen from the figure that maintenance is the sub-part of enterprise and production

system. Maintenance systems have high importance as both depend on it.

• CMMS software helps to manage resources such as labor, spares, tools, information,

cost, and outsourced repair activities. These inputs result in production output,

availability, maintainability, and the safety of assets.

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Question 2
What does CMMS (Computerized Maintenance Management System) primarily aim to

achieve?

A) Increase paperwork in the working environment.

B) Maintain the traditional paper-based record-keeping system.

C) Facilitate the transition from a paper-based to a computerized digital storage system.

D) Discourage the use of digital storage for maintenance records.

E) Promote a hybrid approach of paper and digital record-keeping.

Answer: C) Facilitate the transition from a paper-based to a computerized digital

storage system.

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Benefits of CMMS

Reduce maintenance Reduce maintenance

Reduce overtime
backlog cost

Reduce outsourced Improve maintenance

Reduce follow-up a
contract maintenance planning and
time to repairs
work scheduling

Improve technician Improve technician

Improve maintenance
and service engineer and supervisor
service tracking
performance planning

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CMMS subsystem or modules

Equipment/asset Work order Inventory

register management management

Preventive
Human resource
maintenance
management
(PM) planning

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Equipment/asset register
• It is a database of all the equipment in the plant.

• All maintenance activities are linked to an asset. So, it is linked to all other databases such

as Preventive maintenance (PM) planning, inventory, and purchase

Preventive maintenance (PM) planning

This module contains the PM plan for the registered assets/ equipment based on the

maintenance checklist and frequency.

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Work order management
• The work order is the backbone of the CMMS system.

• A work order can be generated by planned PM or unplanned

maintenance activity.

• All modules are connected and updated through a work order.

Human resources

It Includes personnel and technicians who carry out maintenance work activity.

Inventory management

It includes warehousing, purchase, and ordering of spare parts.

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CMMS software models

LAN-based or
licensed software

Software
Web-based
as-as-service
software
(SaaS) model

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• The LAN-based software is purchased by the company and all the data is stored on the

company servers, major maintenance of parts is carried out by company IT staff or with the

help of a service vendor.

• Web-based software is available through monthly or yearly subscription. Data is stored in

cloud storage and all maintenance activities are carried out by the software provider. In the

next decade, LAN-based CMMS software will be preferred by large organizations while small

organizations will prefer SaaS-based solutions.

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CMMS software
CMMS software vendors can be categorized into two major groups tier 1 and tier 2

Tier 1 Tier 2
SAP Avantis (Schneider Electric)
IBM Maximo Oracle
Infor LN Mainsaver
IFS eMaint
Fiix

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New trends in CMMS or enterprise asset management industry

Industrial internet of
Mobility and things (IoT)
SaaS

Cloud
Blockchain computing

Big data and

advanced analytics

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• Industrial Internet of things (IoT) uses industrial Ethernet for connected devices

concept.

• Cloud computing and big data analytics include the processing of a large amount of

data for predictive analytics using machine learning algorithms.

• Blockchain technology is helping asset management to capture all transactions and

change in the state of the equipment.

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EAM vs. CMMS

• (Enterprise Asset Management) EAM and CMMS were both developed to help

maintain and optimize assets but their scope and impact differ and have evolved

over time.

• Modern EAM solutions take essential CMMS functionality and expand and integrate

it across the core areas of the business, addressing the complete lifecycle of assets,

from initial research and capital planning to eventual disposal or recycling.

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EAM vs. CMMS
• EAM solutions leverage technologies like AI, machine learning, and advanced analytics to

provide real-time insights into asset performance and maintenance needs – and can be

customized to meet the specific needs of different industries and organizations.

• So while CMMS remains a useful and important tool, modern EAM solutions are better

equipped to handle complex and dynamic business needs and deliver a more agile

approach to asset management, helping to best optimize asset usage, reduce costs, and

maximize return on investment.

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Introduction to Asset Performance Optimization
In the mining industry, the efficient performance of assets is critical for achieving operational excellence and

maximizing productivity. Asset Performance Optimization refers to the strategic use of technology, data-driven

insights, and maintenance practices to enhance the reliability, availability, and performance of mining assets.

Understanding the Importance of Asset Performance in the Mining Industry

• Mining companies heavily rely on their assets to carry out various operations, such

as excavation, transportation, and processing. The optimal performance of assets

directly impacts the overall efficiency and profitability of mining operations.

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Role of CMMS Solutions in Enhancing Asset Performance

• Computerized Maintenance Management System (CMMS) solutions play a crucial role

in optimizing asset performance. These advanced software tools help mining

companies efficiently manage maintenance activities, plan preventive maintenance,

and monitor asset health in real-time.

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Key Objectives of Asset Performance Optimization

• The primary objectives of Asset Performance Optimization are to reduce downtime,

minimize maintenance costs, improve equipment reliability, and extend the lifespan of

mining assets. By achieving these goals, mining companies can maximize their return on

investment and ensure sustainable operations.

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Question 3

What are the primary objectives of Asset Performance Optimization in mining?

A) Increase downtime and minimize maintenance costs.

B) Improve equipment reliability and minimize return on investment.

C) Extend the lifespan of mining assets and maximize maintenance costs.

D) Achieve sustainable operations and decrease equipment reliability.

E) Reduce downtime, minimize maintenance costs, improve equipment reliability, and

extend the lifespan of mining assets.

Answer: E) Reduce downtime, minimize maintenance costs, improve equipment reliability,

and extend the lifespan of mining assets.

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Challenges in Asset Management for the Mining Sector
The mining industry faces various challenges in effectively managing its diverse and extensive asset portfolio.

These challenges can hinder asset performance and lead to increased maintenance costs and downtime.

Managing a Vast and Complex Asset Portfolio

Dealing with High Maintenance Costs and Downtime

Ensuring Regulatory Compliance and Safety Standards

Addressing the Impact of Environmental Factors on Assets

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Managing a Vast and Complex Asset Portfolio

Mining operations typically involve a wide range of assets, including heavy machinery,

vehicles, conveyor systems, and processing equipment. Managing this vast and complex

asset portfolio can be overwhelming without proper tools and strategies.

Dealing with High Maintenance Costs and Downtime

Maintenance costs can constitute a significant portion of a mining company's expenses.

Unscheduled downtime due to asset failures can disrupt production schedules and result

in financial losses.

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Ensuring Regulatory Compliance and Safety Standards

The mining industry is subject to strict regulatory requirements and safety standards.

Non-compliance can lead to penalties and reputational damage.

Addressing the Impact of Environmental Factors on Assets

Mining assets are exposed to harsh environmental conditions, such as extreme

temperatures, dust, and moisture. These factors can accelerate wear and tear, leading to

premature asset failures.

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 Benefits of CMMS Solutions for Mining Companies
Implementing CMMS solutions in mining operations can yield numerous benefits, enhancing equipment

reliability, maintenance efficiency, and overall asset management.

Enhanced
Improved Equipment Real-time Monitoring Streamlined Data-Driven Decision
Maintenance
Reliability and and Condition-Based Inventory and Spare Making and
Planning and
Availability Maintenance Parts Management Predictive Analytics
Scheduling

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Improved Equipment Reliability and Availability

CMMS solutions enable mining companies to implement effective preventive maintenance

programs, reducing the likelihood of unexpected breakdowns and improving equipment reliability

and availability.

Enhanced Maintenance Planning and Scheduling

CMMS tools provide advanced planning and scheduling features, allowing maintenance teams to

optimize work orders, allocate resources efficiently, and reduce downtime.

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Real-time Monitoring and Condition-Based Maintenance

With IoT integration, CMMS solutions enable real-time monitoring of asset performance and

condition-based maintenance, allowing for timely interventions and minimizing equipment

failures.

Streamlined Inventory and Spare Parts Management

CMMS systems help streamline inventory management by providing accurate asset data,

ensuring the availability of spare parts when needed, and reducing inventory holding costs.

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Data-Driven Decision Making and Predictive Analytics

CMMS solutions leverage data analytics and predictive maintenance algorithms to

identify patterns, detect anomalies, and provide data-driven insights for informed

decision-making.

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Key Features of CMMS for the Mining Industry
CMMS solutions designed for the mining industry offer a comprehensive set of features tailored to meet the

specific needs of asset-intensive mining operations.

Asset Tracking and Historical

Maintenance Data

Work Order Management and

Task Assignment

Preventive Maintenance and

Inspection Checklists

Integration with IoT Sensors

and Predictive Maintenance

Mobile Access and Remote

Workforce Management

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Asset Tracking and Historical Maintenance Data
CMMS systems track the complete maintenance history of mining assets, including past work

orders, repairs, and inspections. This historical data helps in identifying recurring issues and

planning preventive maintenance.

Work Order Management and Task Assignment

CMMS solutions streamline work order management, enabling maintenance teams to create,

assign, and track tasks efficiently. This feature ensures that maintenance activities are carried

out promptly and in a structured manner

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Preventive Maintenance and Inspection Checklists
CMMS platforms allow the creation and scheduling of preventive maintenance tasks,

along with detailed inspection checklists. Regular inspections and maintenance activities

help prevent unexpected breakdowns and extend asset life.

Integration with IoT Sensors and Predictive Maintenance

CMMS solutions can integrate with IoT sensors and other data sources to gather real-time

asset performance data. This integration enables predictive maintenance, allowing mining

companies to address potential issues before they escalate.

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Mobile Access and Remote Workforce Management

Mobile CMMS applications enable technicians to access maintenance information on the

go, carry out inspections, and update work orders in real-time. Remote workforce

management ensures efficient collaboration among team members.

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Implementing CMMS in Mining Operations
The successful implementation of a CMMS system in a mining operation requires careful planning,

stakeholder involvement, and change management.

Overcoming
Resistance to
Training and Change and
Skill Ensuring
Development for Adoption
Developing a
Comprehensive Maintenance
Implementation Teams
Selecting the
Right CMMS Strategy
Assessing the Solution for
CMMS Specific Mining
Implementation Needs
Readiness

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Assessing the CMMS Implementation Readiness

Prior to implementation, mining companies should assess their readiness for CMMS

adoption. This involves evaluating existing processes, data quality, and the availability of

resources.

Selecting the Right CMMS Solution for Specific Mining Needs

Choosing a CMMS solution that aligns with the unique requirements of mining operations

is essential. Key factors to consider include scalability, integration capabilities, and

industry expertise of the vendor.

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Developing a Comprehensive Implementation Strategy

Successful CMMS implementation requires a well-defined strategy that includes setting clear

goals, establishing timelines, allocating resources, and defining roles and responsibilities.

Training and Skill Development for Maintenance Teams

Proper training and skill development are crucial for ensuring that maintenance teams can

effectively use the CMMS system and leverage its features to the fullest.

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Overcoming Resistance to Change and Ensuring Adoption

CMMS implementation may face resistance from employees accustomed to

traditional maintenance practices. Effective change management is necessary to

overcome resistance and ensure adoption.

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Future Trends in CMMS for the Mining Industry
The mining industry is evolving, and future trends in CMMS solutions are poised to

revolutionize asset management practices.

AI and Machine Learning for Predictive Maintenance

Advancements in AI and machine learning will enable more accurate predictive

maintenance, minimizing asset failures and optimizing maintenance schedules

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Advanced Data Analytics for Performance Optimization

CMMS solutions will leverage advanced data analytics to provide deeper insights into asset

performance, enabling proactive decision-making.

Robotics and Automation in Asset Management

The mining industry may witness the integration of robotics and automation technologies to handle

routine maintenance tasks and inspections.

Cloud-Based CMMS Solutions and Scalability

Cloud-based CMMS platforms will become more prevalent, offering scalability and

easy access to data for geographically dispersed mining operations.

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• Bagadia, K. (2010). Computerized Maintenance Management Systems Made Easy:
How to Evaluate, Select, and Manage CMMS. United Kingdom: McGraw Hill LLC.
https://www.google.co.in/books/edition/Computerized_Maintenance_Management_
Syst/UNeYRMCXG3oC?hl=en&gbpv=0
• Robatto Simard, S., Gamache, M., & Doyon-Poulin, P. (2023). Current Practices for
Preventive Maintenance and Expectations for Predictive Maintenance in
East-Canadian Mines. Mining, 3(1), 26-53.
• https://uis.brage.unit.no/uis-xmlui/bitstream/handle/11250/2561926/Ashraf_Waqas.p
df?sequence=1
• https://www.theseus.fi/bitstream/handle/10024/139395/laurila_jari.pdf;jsessionid=09
9663C2A6ABD27585541BA8399F65D2?sequence=1

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• https://www.maintwiz.com/blog/maximizing-asset-performance-cmms

• https://limblecmms.com/cmms/

• https://adaptahome.co.uk/product/planned-preventative-maintenance/

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• Discussed about the maintenance and its types.

• Introduced the concept of managing maintenance processes in various industries.

• Explored the foundational steps involved in effective maintenance management.

• Introduced the Computerized Maintenance Management System (CMMS).

• Examined the advantages, such as enhanced efficiency and streamlined maintenance processes.

• Explored the different functional modules within a CMMS.

• Discussed various models of CMMS software applications.

• Introduced the software used for implementing CMMS.

• Explored emerging trends in the CMMS and Enterprise Asset Management (EAM) industry.

• Highlighted the distinctions between Enterprise Asset Management and CMMS systems.

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• Introduced the concept of optimizing asset performance for efficiency.

• Addressed challenges specific to asset management in the mining sector.

• Examined the advantages of Computerized Maintenance Management Systems in mining

operations.

• Explored essential features tailored for the mining industry within CMMS solutions.

• Discussed the process of integrating CMMS into mining operations for improved efficiency.

• Explored evolving trends shaping the future of CMMS in the mining industry.

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