An Introduction to Maintenance

Mr Paul Dobie
 Objectives
 Understand the different types of maintenance and the
benefit of using each one.
 Recognise the criteria for selection of appropriate
maintenance approaches.
 Understand the importance of maintenance
management systems for maintenance optimisation.
Why do Maintenance?
Prevent performance deterioration or restore
performance to optimum levels
Prevent machine from breaking down or repair a
broken machine.
To increase reliability and availability of production
or service.
Extend working life of machine.
Enable high disposal value.
Avoid high business impact failures.
 Maintenance failures – High impact

Piper Alpha
Deep water Horizon

Union Carbide plant, Bhopal

 Why do Maintenance?
Maintenance is done to avoid failure or maintain
the function of the equipment in good order.
Equipment will be able to carry out its intended
purpose.
There are consequences if maintenance is not
conducted correctly or timely.
Maintenance is a word with which most people
are familiar – e.g. Boiler / car maintenance.
 Why do Maintenance?
TO MAXIMISE COMPANY PROFITS
 Maintenance can cost between 10 and 45 % of operating cost.

 It should be viewed as an OPPORTUNITY to increase profit

through improved processes and reducing maintenance costs.

 In USA alone, more than $300 billion is spent by companies on

maintenance – Significant potential to manage and reduce
costs by improved processes.
History of Maintenance
 Evolution of Maintenance
Reactive Preventative Predictive

I know it will It needs to have

It Broke
break someday maximum availability

Regular monitoring
Decide when to
Fix It and identify any need
perform maintenance
for fixing

High cost Low cost

 Maintenance planning is key
Need both technical organisation and
administrative systems in place for maintaining
equipment.
Maintenance actions can be split into two
distinct categories:
– those organized with a logical and predetermined
administrative plan of action. (Maximise)
– those without a logical and predetermined
administrative plan (Minimise but recognise)
 Types of maintenance
Terotechnology Philosophy

Maintenance Area

Planned Unplanned Strategy

Maintenance Maintenance

Total Reliability
Preventative
Productive Centred
Maintenance Approach
Maintenance Maintenance

Condition
Scheduled Corrective Emergency
Based
Maintenance Maintenance Maintenance
Maintenance
Types of maintenance
Terotechnology Philosophy

Maintenance Area

Planned Unplanned Strategy

Maintenance Maintenance

Total Reliability
Preventative
Productive Centred
Maintenance Approach
Maintenance Maintenance

Condition
Scheduled Corrective Emergency
Based
Maintenance Maintenance Maintenance
Maintenance
 Unplanned Maintenance
This strategy is often known as 'run to failure’ –
Basically it is 'do nothing until it breaks' option.
• The direct costs can be same
or less value compared to Direct Costs

planned maintenance
• There are many indirect costs
whose value is not known till
the failure occurs.
• Reputational cost of not
meeting customer demand Indirect Costs

can be very high.

 Corrective Maintenance
Failure of the equipment which brings operation
to a halt.
Requires the equipment to be repaired before
operation / production can restart.
In essence corrective maintenance is (BS
3811:1993):
– The maintenance carried out after a failure has
occurred and is intended to restore an item to a state
in which it can perform its required function.
 Corrective Maintenance types
Rebuild – Complete disassembly and repair /
replacement or worn / unserviceable parts.
Overhaul – Restoring to maker standard using
inspect and repair only as appropriate.
Servicing – Can be as simple as filling up air in car
tyre or replacement of a filter.
Salvage – Disposal of non repairable material
and use of salvaged material.
 Emergency maintenance
This approach to maintenance is often confused
with corrective maintenance, however its precise
definition illustrates the difference between the
two (BS 3811:1993):
– Emergency maintenance is the maintenance which it
is necessary to put in hand immediately to avoid
serious consequences.
– (Note: often done under pressure but a return to optimum
levels must be ensured - Lac-Mégantic rail disaster)
Unplanned Maintenance – best option?
Unplanned or breakdown maintenance is
suitable in circumstances where ;
– Components fail randomly and provide no prior
indication of impending failure.
– Unscheduled stoppages cause minimal inconvenience
– Advantage lies in the fact that under these conditions,
it may well be a low cost option.
 Types of maintenance
Terotechnology Philosophy

Maintenance Area

Planned Unplanned Strategy

Maintenance Maintenance

Total Reliability
Preventative
Productive Centred
Maintenance Approach
Maintenance Maintenance

Condition
Scheduled Corrective Emergency
Based
Maintenance Maintenance Maintenance
Maintenance
Maintenance exercise
Using the slides, moodle and internet resources
prepare a 10 minute presentation on the
following topic:
Group 1: RCM
Group 2: CBM
Group 3: TPM
Group 4: Maintenance & software systems –
High level review of applications and benefits.
 Types of maintenance
Terotechnology Philosophy

Maintenance Area

Planned Unplanned Strategy

Maintenance Maintenance

Total Reliability
Preventative
Productive Centred
Maintenance Approach
Maintenance Maintenance

Condition
Scheduled Corrective Emergency
Based
Maintenance Maintenance Maintenance
Maintenance
 Planned Maintenance
In contrast to the previous strategy, planned
maintenance is (BS 3811:1993):
– The maintenance organized and carried out with
previous planning, control and the use of records to a
predetermined plan.
Encapsulated within this formal definition is the
implied management of the maintenance
function.
 Preventative Maintenance
The formal definition of preventive maintenance
is (BS EN 13306:2017):
– The maintenance carried out intended to assess
and/or mitigate degradation and reduce the
probability of failure of an item.
Elements of Preventative Maintenance
Inspection - Periodically inspecting materials/items to determine
their serviceability by comparing to expected standards
Servicing - Cleaning, lubricating, charging, etc., of items/ materials
periodically to prevent the occurrence of incipient failures
Calibration - Periodically determining the value of characteristics
of an item by comparison to a standard.
Adjustment - Periodically adjusting specified variable elements of
material to achieve optimum system performance
Testing - Periodically checking out to determine serviceability and
detect electrical/mechanical-related degradation
 Preventative Maintenance
It is important to optimize use of preventive
maintenance, in a cost-effective sense, by
identifying:
– The appropriate safety critical machinery on which it can
be effectively used.
– The most efficient method of determining the time
interval or criterion which dictates when it should be
undertaken.
 Preventative Maintenance
This has resulted in preventive maintenance to
follow two traditional approaches:
• Scheduled maintenance and
• condition-based maintenance.
Subsequently, two additional approaches have
found favour in some sectors of manufacturing
industry:
• Reliability Centred Maintenance (RCM) and
• Total Productive Maintenance (TPM).
 Scheduled maintenance
This approach attempts to prevent breakdown by carrying out
maintenance before the failure interval exhibited by a
component or machine.
Maintenance interval is set initially by the maker. Amendments
can be made based on equipment performance and
experience.
Thus the definition of scheduled maintenance is (BS
3811:1993):
– The preventive maintenance carried out to a predetermined interval
of time, number of operations, mileage etc.
Health Management and Monitoring Systems
Fixed interval scheduled maintenance programs have been a
scheduled maintenance mainstay for over 70 years.
Health Management and Monitoring Systems (HMMS) are the
maintenance technology of the future.
E.g. These systems are being used for new generation aircraft
such as the Boeing’s 747, 787 and Airbus A380.
HMMS incorporates innovative, imbedded sensors, to provide
continual real-time systems and structures health assessments
HMMS incorporates on-board state-of-the-art structural and
systems integrity computer programs with decision making
capabilities
HMMS
 Condition-Based Maintenance
It seeks to determine the actual operating condition of a
system or component at any point in time.

Formally condition-based maintenance is defined as (BS

3811:1993):
– The preventive maintenance initiated as a result of knowledge
of the condition of an item from routine or continuous
monitoring.
 Condition Based Monitoring
Vibration analysis
Thermography
Lubricant and fluid analysis
Ultrasonic testing
Vibration Analysis

Early detection of
mechanical fatigue and
breakdown
Vibration Analysis

Avoiding disassembly and

averting unplanned downtime
 THERMOGRAPHY SURVEY
A widely used tool in all facets of industry to
measure anywhere a fault can be predicted by a
temperature differential.
Non-destructive tool in the analysis and
evaluation of electrical distribution equipment.
Reference point of equipment temperature
under normal operating conditions.
Eg - Electrical switchboards, high temperature
operating conditions such as Turbochargers
Thermograph – Motor Bearing failure
 OIL ANALYSIS
Oil Analysis is a non-destructive test used to assess the condition of
lubricants compared to oil maker standard parameters.
Oil analysis trending over time is one of the most powerful
predictive tools for identifying potential failures.
3 basic categories of elements affecting the lubrication
effectiveness: wear metals, contaminants, and additives.
Early detection with oil analysis can allow for corrective action
before major damage occurs.
One of the major advantages of an oil analysis program is being
able to anticipate problems and schedule repair work.
 OIL ANALYSIS

Benefits
Improve oil sampling methods
with emerging technologies
Improve machine condition and
reliability with oil analysis
Increase the remaining useful
life of your lubricant
Reduce maintenance costs
associated with unplanned
downtime
Ultrasound
CBM - Applications
Failure patterns & maintenance approach
Investigations were conduced into past aircraft
maintenance history of the 727 aircraft by
Boeing
It was found that all failures fitted one of six
probability (or likelihood of occurrence) failure
curves.
The USA navy conducted similar investigations
and confirmed the findings of the airline
industry.
Failure patterns - which maintenance approach?
Failure patterns – and fixed interval approach

Fixed interval replacement or overhaul of items

is only appropriate for items that do display
wear-out characteristics (A,B & C)
At best, performing fixed interval overhauls or
replacement of items that do not wear out (E) is
a complete waste of time and money
Fixed interval approach may actually reduce
equipment reliability, rather than improve it (F).
P-F Curves
A type of deterioration model that utilizes a graph
to represent the relationship between potential
failure ("P") and functional failure ("F").
P-F curves are used to map and avert failures.
An understanding of the P-F curve helps the
owner determine which types of asset
replacement policy is most appropriate to their
tolerance for risk.
P-F Curves – Replacement Policies
P-F Curves – Replacement Policies
Types of maintenance - RCM
Terotechnology Philosophy

Maintenance Area

Planned Unplanned Strategy

Maintenance Maintenance

Total Reliability
Preventative
Productive Centred
Maintenance Approach
Maintenance Maintenance

Condition
Scheduled Corrective Emergency
Based
Maintenance Maintenance Maintenance
Maintenance
 Reliability Centred Maintenance
The concept of RCM originated in the airline industry.
Driven by cost of safety-driven, failure preventive
servicing programmes and poor aircraft availability.
RCM been defined as
– A systematic approach to quantitatively assessing the
need to perform or revise preventive maintenance tasks
and plans.
 Key Features of RCM
The objective of RCM is the preservation of
System Function,
…not Equipment Function
• Focuses on System Functions and failure of
those Functions
• Only chooses Applicable & Effective
Maintenance
 Key Features of RCM
Considers all different ways a system can fail to
provide its necessary functions (and priority)
Consider failure modes of a hydraulic system:
Total loss of hydraulic pressure / flow
Partial loss of hydraulic pressure / flow
Minor leak of fluid

There is usually more than one failure mode

associated with a particular system function – hence
there is more than one criticality
 Key Features of RCM
Chooses Applicable & Effective Maintenance

Applicable
– Prevent or reduce risk of failure
– Detect onset of failure
– Discover hidden failure
Effective
– Cost effective
 RCM Methodology
1. System selection and information collection
2. System boundary definition
3. System description and functional block diagram
4. System functions and functional failures
5. Failure Mode and Effects Analysis (FMEA)
6. Logic (decision) tree analysis (LTA)
7. Maintenance Task Selection
 Effectiveness of RCM
Nuclear Power Industry / Oil & gas industry — 30-40% cost
savings
Electricity Industry — reduced outage, saving $500,000 -
$750,000 per day
Choosing Types of Maintenance
 Types of maintenance - TPM
Terotechnology Philosophy

Maintenance Area

Planned Unplanned Strategy

Maintenance Maintenance

Total Reliability
Preventative
Productive Centred
Maintenance Approach
Maintenance Maintenance

Condition
Scheduled Corrective Emergency
Based
Maintenance Maintenance Maintenance
Maintenance
 TPM definition
A company-wide team-based effort to build quality into equipment and to
improve overall equipment effectiveness

Total
– all employees are involved
– it aims to eliminate all accidents, defects and breakdowns

Productive
– actions are performed while production goes on
– troubles for production are minimized

Maintenance
– keep in good condition
– repair, clean, lubricate
 TPM definition
TPM combines the traditionally practice of preventive
maintenance with:
1) Total Quality Control and
2) Total Employee Involvement,
to create a culture where operators develop ownership
of their equipment, and become full partners with
Maintenance, Engineering and Management to assure
equipment operates properly everyday.
 TPM principles
Increase Overall Equipment Effectiveness (OEE)
Improve existing planned maintenance systems
The operator is the best condition monitor
Provide training to upgrade operations and
maintenance skills
Involve everyone and utilize cross-functional
teamwork
 Autonomous Maintenance

Planned Maintenance

Equipment and process

improvement
Eight major pillars of TPM

Early management of
new equipment
Education and training

Process quality management

Safety and environmental management

TPM in the office

 Maintenance systems
Many software systems exist to support maintenance
–Enterprise Asset Management Systems
–Equipment Maintenance Systems
–Maintenance Management Systems
–Computerised Maintenance Management Systems
All basically the same.
All provide decision tools about maintenance.
All provide “dashboard” facilities to monitor conditions
What do these systems do?
Maintains information about an organization’s
maintenance operations.
– Problem Tracking (Call centre/Maintenace Centre)
– Work Orders (Reactive/Corrective & PM)
– Inspections
– Asset Inventory & Management
– Inventory Control (Parts / Materials)
– Permits
How do maintenance systems help?

Addresses business Increased Efficiencies &

challenges Informed Decisions

–Productivity – Asset Inventory

enhancements – Maintenance History
–Maximizing asset life – Human Resources
cycles – Financial Impacts
–Minimizing total cost of – Regulatory Compliance &
ownership Accreditation
 eMaintenance
Automatic Failure Detection,
Automatic Analysis, Automatic Reporting

CMMS
Computerized Maintenance Management System
Manual Failure Detection,
Automatic Analysis, Manual Reporting

Conventional Maintenance
Manual Failure Detection,
Manual Analysis, Manual Reporting
 eMaintenance

With eMaintenance, managers make Advantages of eMaintenance

decisions based on real time information. – Unprecedented Transparency (no
human inputs)
Decision makers at any level may access
– High efficiency (data at finger tips,
up to date information from their
fully automated)
desktops instead of relying on human- – High availability (Fast response, Low
generated reports. Downtime)
Contractors receive failure alerts through – Satisfied Clients (less complaints)
SMS & email rather than through client
complaints.
Video
Many competing software packages
to increase maintenance efficiency ..
 Selection of Maintenance Strategy

Understand the company strategy and philosophy

Understand the priorities and key focus areas
Identify which type of maintenance for each
machine group best suits operation / production /
service requirements to achieve these priorities
Identify the best combination of maintenance
management strategies
Questions ?