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Conclusion
DEFINITIONS Maintenance management involves planning, organizing and controlling of all maintenance resources to adjust, repair, replace and modify, technical systems, that these systems should perform, its intended function for a specified period --Visser Maintenance management can be considered as the direction and organization of resources in order to control the availability and performance of an plant to some specified level -- Kelly
MAINTENANCE STRATEGY
Integration of complementary techniques to meet the goals of optimum equipment reliability and availability for the least maintenance and operating cost.
APPROACH TO MAINTENANCE UNPLANNED PLANNED
PROACTIVE MAINTENANCE
MAINTENANCE PHILOSOPHIES
Reactive and Corrective Maintenance Reactive and Preventive Maintenance Proactive and Predictive or Condition Based Maintenance Reliability Centred Maintenance and TPM
1960s
1990s
REACTIVE MAINTENANCE
Allow Machinery to run to failure The exclusive maintenance mode up until the last decade Continues to be the predominate method of maintenance. A recent survey showed that >50% of the major industrial companies are still operating in this mode.
RUN TO FAILURE
Timeline to Failure
Stressor Applied
Failure
6 Months
ADVANTAGES
DISADVANTAGES
Increased costs due to unplanned downtime of equipment. Increased labor costs, especially if overtime is needed. Costs involved with repair or replacement of equipment. Possible secondary equipment or process damage from equipment failure. Inefficient use of staff resources. Does not support the true definition of maintenance.
NO
Will the breakdown be more costly than prevention? NO Is equipment in the critical path for manufacturing? NO Is backup equipment unavailable ? NO Will the breakdown adversely affect delivery or customer service? NO Will the breakdown further damage the equipment? NO REACTIVE MAINTENANCE JUSTIFIED
P R E V E N T I V E M A I N T E N A N C E
PREVENTIVE MAINTENANCE
Actions that detect, preclude, or mitigate degradation of a component or system with the aim of sustaining or extending its useful life through controlling degradation to an acceptable level.
Timeline to Failure
Stressor Applied
Failure
PM Interval
PM Interval
24 Months Time-Directed Tasking: Proven to save 12% - 18% over Run to Failure
Preventive Maintenance
Scheduled maintenance activities are based on specific time intervals (sometimes referred to as Periodic Maintenance)
Calendar days Run time Parts produced
Cost effective in many capital intensive or potentially high impact processes. Flexibility allows for the adjustment of maintenance periodicity. Increased component life-cycle. Energy savings. Reduced equipment or process failures.
Advantages
Disadvantages
Catastrophic failures still likely to occur. Labor intensive. Performance of unneeded maintenance. Incidental damage to components through
Predictive Maintenance
Measurements that detect the onset of a degradation mechanism thereby allowing causal stressors to be eliminated or controlled prior to any significant deterioration in the component physical state. Results indicate current and future functional capability.
Schedule maintenance activities when mechanical or operational conditions warrant to repair or replace deteriorated equipment before obvious problems occur.
Predictive Maintenance
Timeline to Failure
Stressor Applied
Failure
Vibration Monitoring and Analysis One of the most commonly used techniques. Helps determine the condition of rotating equipment and structural stability in a system. Conditions monitored: wear, imbalance, misalignment, mechanical looseness, bearing damage, belt flaws, cavitations, fatigue, etc. Infrared Thermography (IRT) Application of infrared detection instruments to identify pictures of temperature differences It is a non-contact technique Attractive for identifying hot/cold spots in energized electrical equipment, large surface areas such as boilers and building walls, and other areas where stand off temperature measurement is necessary.
Methods to Assess Condition of Systems/Equipment Lubricant and Wear Particle Analysis Is performed for three reasons: To determine the mechanical wear condition To determine the lubricant condition To determine if the lubricant has become contaminated Standard analytical tests include: visual and odor, viscosity, % solids/water, spectrometric metals, infrared spectroscopy, particle counting, analytical ferrography, etc. Passive (Airborne) Ultrasonics Airborne ultrasonic devices operate in a frequency range of 20kHz-100kHz and heterodyne the high frequency signal to the audible range to allow the operator to hear changes in noise associated with leaks, corona discharges, and other high frequency events. Examples include bearing ring and housing resonant frequency excitation caused by insufficient lubrication and minor defects.
Methods to Assess Condition of Systems/Equipment Non-Destructive Testing (NDT) Evaluates material properties and quality of manufacture for high-value components or assemblies without damaging the products or its function. Examples are: radiography, ultrasonic testing (imaging), magnetic particle testing, dye penetrant, hydrostatic testing and electromagnetic induction testing Radiography ( or X-Ray): Detection of deep-surface defects. One of the most powerful NDT techniques available in industry. Depending on the strength of the radiation source, can provide a clear representation of discontinuities or inclusions in material several inches thick. Applicable to metal components including weld points. Ultrasonic Testing (Imaging) (UT): Detection of deep sub-surface defects Alternative of complementary technique to radiography. Based on the difference in the wave reflecting properties of defects and the surrounding material Applicable to same components as X-Ray testing. Specialized applications for plastics or composite materials are common. Preferred method over radiography due to expense and safety precautions required by radiography. iii) Magnetic Particle Testing (MT): Detection of shallow sub-surface defects. Useful during localized inspections of weld areas and specific areas of high stress or fatigue loading The major advantage is its portability and speed of testing. Applicable to materials that conduct electric current and magnetic lines of flux. Most effective in welded areas.
Dye Penetrant (DP): Detection of surface defects in non-porous materials. Allows large areas to be quickly inspected. Simplest NDT technique in which to gain proficiency v) Hydrostatic Testing: Method for detecting defects that completely penetrate pressure boundaries. Typically conducted prior to delivery or operation of completed systems or sub-systems that act as pressure boundaries. Applicable in components and assembled systems that contain fluids or gases.
Electromagnetic Induction Testing or Eddy Current Testing: Provides a portable and consistent method for detecting surface and shallow sub-surface defects in metal components, such as cracks, seams, holes or lamination separation). electrical plates A set of magnetizing coils are used to induce currents into the component being tested. Used for monitoring the thickness of metallic sheets, and tube walls.Also coating thickness.
In more production oriented applications, this technique can determine material composition, uniformity and thickness of materials being produced.
ACOUSTIC EMISSION
Acoustic emission is a technique to monitor defect formation and failures in structural materials used in services or laboratories. Moreover, the method has been developed and applied in numerous structural components, such as steam pipes and pressure vessels, and in the research areas of rocks, composite materials, and metals. Most of the techniques available uses the traditional ways, which only captures acoustic-emission parameters, including acoustic-emission counts, peak levels, and energies. These parameters can be correlated with the defect formation and failures. Some of the researchers analyze the waveforms of acoustic emission as functions of sources and wave-propagation mechanisms. Above all, acoustic emission was found to be an effective way of detecting fatigue and fracture behaviors of materials.
Build a preventive maintenance system. Build a Predictive maintenance system. Evaluate the planned maintenance system.
RCM Goals and Objectives Identify for each system and equipment the failure modes and their consequences Determine the most cost-effective and applicable maintenance technique to minimize the risk and impact of failure
RCM Analysis
What does the system or equipment do?
n io adverse effect on safety or critical mission operations? cis ee e r D T No Yes CM ogic R L Can redesign solve the problem Is the item expendable?
No Yes No Is there predictive technology (e.g. vibration testing or (thermography) that will monitor the condition and give sufficient warning(alert/alarm) of an impending failure? No Yes No Yes Yes
Is there an effective PM task that will minimize functional failure? No Is establishing redundancy cost and priority-justified? No Accept risk Yes Install redundant unit(s) Yes
RCM Principles
is function oriented is system focused is reliability centered acknowledges design limitations is driven by safety and economics defines failure as any unsatisfactory condition uses a logic tree to screen maintenance tasks tasks must be effective tasks must be applicable acknowledges 3 types of maintenance is a living system
R C M
*Conduct awareness training * Target Physical Resources * Develop project Plans *Estimate cost/benifit
Phase I: Prepare
Phase II:Demonstrate
Phase III:Execute
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
Everyday Maintenance Periodic Maintenance Instant Maintenance Corrective Maintenance Preventative Maintenance Predictive maintenance Pro-active maintenance Autonomous Maintenance Reliability Centered Maintenance
Autonomous Maintenance
Includes any activity performed by the production department that has a maintenance function and is intended to keep the plant operating efficiently in order to meet production plans. Goals: Prevent equipment deterioration through correct operation and daily checks Bring equipment to its ideal state through restoration and proper management Establish the basic conditions needed to keep equipment well-maintained
Equipment uptime: up 40% Unexpected equipment breakdowns: down 99% Equipment speed: up 10% Defects caused by equipment: down 90% Equipment output (productivity): up 50% Maintenance costs: down 30% Return on investment: several hundred percent Safety: approaching zero accidents Job satisfaction: much better
E. I. Dupont
Widely recognized for outstanding safety record as well as its vigorous approach to benchmarking. Learned of TPM processes before most other North American companies. Organized an internal staff function, the Corporate Maintenance Leadership Team (CMLT), responsible for helping plants improve equipment management. Decided that maintenance needed to be view strategically in order for it to support overall corporate goals. Developed a vision of success and the establishment of a process to achieve that vision. Established an internal award system that recognizes excellence in equipment management