ZESCO LIMITED DISTRIBUTION AND SUPPLY

TYPES OF MAINTENANCE PROGRAMS

Maintenance Planner Technical Services (CBD) Samuel Ndopu sndopu@zesco.co.zm

Content
Introduction

Maintenance definition Need for maintenance Maintenance type structure Areas of maintenance
Types of Maintenance: Reactive Maintenance (Breakdown) Preventive Maintenance (Time-based) Predictive Maintenance (Condition-based) Reliability Centered Maintenance (Pro-active) Overview of other Maintenance types

Maintenance Definition
The dictionary defines maintenance as follows: The work of keeping something in proper condition; upkeep.
British Standard Glossary of terms (3811:1993) defined maintenance as: the combination of all technical and administrative actions, including supervision actions, intended to retain an item in, or restore it to, a state in which it can perform a required function. This would imply that: Maintenance should be actions taken to prevent a device or component from failing or to repair normal equipment degradation experienced with the operation of the device to keep it in proper working order.

Need for Maintenance

The need for maintenance is predicated on actual or impending failure ideally, maintenance is performed to keep equipment and systems running efficiently for at least design life of the component(s). The practical operation of an equipment or component is time-based function. If one were to graph the failure rate a component population versus time, it is likely the graph would take the bathtub shape shown

Bathtub

Equipment periods of operation

The initial infant mortality period of bathtub curve is characterized by high failure rate followed by a period of decreasing failure. Many of the failures associated with this region are linked to poor design, poor installation, or misapplication.

The constant failure rate period known as useful life. It is observed that poor O&M often plays significant role. It is also generally agreed that exceptional maintenance practices encompassing preventive and predictive elements can extend this period.
The wear-out period is characterized by a rapid increasing failure rate with time. In most cases this period encompasses the normal distribution of design life failures.

Maintenance type structure

MAINTENANACE

PLANNED MAINTENANCE

UNPLANNED MAINTENANCE (Reactive)

EMERGENCY

BREAKDOWN

PREDICTIVE MAINTENANCE

PREVENTIVE MAINTENANCE

RCM MAINTENANCE

STATISTICAL BASED

CONDITION BASED

Areas of Maintenance
Civil maintenance :Building construction and maintenance, maintaining service facilities such as water, gas steam, heating, ventilating, A.C., painting, plumbing and carpentry work. Also include fire fighting equipments. Mechanical maintenance: Maintaining machines and equipments, transport vehicles, material handling equipments, steam generators, boilers, compressors and furnaces, lubricating the machines is also part of mechanical maintenance work.

Electrical maintenance: Maintaining electrical equipments such as generators, transformers, switch gears, motors, telephone systems, electrical installations, lightings, fans, meters, gages instruments, control panels and battery charging.

Information System maintenance:

Maintaining components of a computer system.

Hardware

Computer System

Software
Data Networks

Examples of hardware

Reactive Maintenance
Reactive maintenance is

basically the Run it, till it breaks or Run to fail maintenance mode. No actions or efforts are taken to maintain the equipment as the designer originally intended to ensure design life is reached. All maintenance work unplanned. Example: Light bulb replacement. Advantages Low cost maintenance. Less staff.

Disadvantages Increased cost due to unplanned downtime of equipment. Increased labor cost, especially if overtime is needed. Cost involved with repair or replacement of equipment. Possible secondary equipment or process damage from equipment failure. Inefficient use of staff resources.
Breakdown Causes Basic conditions neglected. Inadequate skills. Operating standard not followed. Deterioration unchecked. Inherent design weakness

Planned Maintenance
The goal of planned maintenance is to achieve the absolute minimum amount of needs for effective maintenance. Planed Maintenance Technique: Definition: It is a system of activities in which all staff work to improve up-time, quality of output and reduce maintenance cost through the continuous improvement of equipment operation. Including preventive and predictive scheduled maintenance programs.

Predictive Maintenance
Predictive maintenance can be defined as follows: Measurements that detect the onset of system degradation (lower functional state), 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.
Basically, predictive maintenance differs from preventive maintenance by basing maintenance need on the actual condition of the machine rather than on some preset schedule. You will recall that preventive maintenance is time-based. Activities such as changing lubricant are based on time, like calendar time or equipment run time.

Advantages Increased component operational life/availability. Allows for preemptive corrective actions. Decrease in equipment or process downtime. Decrease in costs for parts and labor. Better product quality. Improved worker and environmental safety. Improved worker morale. Energy savings.

Disadvantages Increased investment in diagnostic equipment. Increased investment in staff training. Savings potential not readily seen by management.

Preventive Maintenance
Preventive maintenance can be defined as follows: Actions performed on a time- or machine-run-based schedule 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.

Advantages Cost effective in many capital-intensive processes. Flexibility allows for the adjustment of maintenance periodicity. Increased component life cycle. Energy savings. Reduced equipment or process failure. Disadvantages Catastrophic failures still likely to occur. Labor intensive. Includes performance of unneeded maintenance. Potential for incidental damage to components in conducting unneeded maintenance.

Reliability Centered Maintenance

Reliability centered maintenance (RCM) magazine provides the following definition of RCM: a process used to determine the maintenance requirements of any physical asset in its operating context. Basically, RCM methodology deals with some key issues not dealt with by other maintenance programs. It recognizes that all equipment in a facility is not of equal importance to either the process or facility safety. It recognizes that equipment design and operation differs and that different equipment will have a higher probability to undergo failures from different degradation mechanisms than others. It also approaches the structuring of a maintenance program recognizing that a facility does not have unlimited financial and personnel resources and that the use of both need to be prioritized and optimized.

Advantages Can be the most efficient maintenance program. Lower costs by eliminating unnecessary maintenance or overhauls. Minimize frequency of overhauls. Reduced probability of sudden equipment failures. Able to focus maintenance activities on critical components. Increased component reliability. Incorporates root cause analysis.

Disadvantages Can have significant startup cost, training, equipment, etc. Savings potential not readily seen by management.

How to Initiate Reliability Centered Maintenance

The road from a purely reactive program to a RCM program is not an easy one. The following is a list of some basic steps that will help to get moving down this path. Develop a Master equipment list identifying the equipment in your facility. Prioritize the listed components based on importance or criticality to operation, process, or mission see text box highlighting priority scheme. Assign components into logical groupings.

Determine the type and number of maintenance activities required and periodicity using: o Manufacturer technical manuals o Machinery history o Root cause analysis findings - Why did it fail? o Good engineering judgment Assess the size of maintenance staff. Identify tasks that may be performed by operations maintenance personnel. Analyze equipment failure modes and impacts on components and systems. Identify effective maintenance tasks or mitigation strategies.

Reactive Maintenance (Breakdown or Run-toFailure Maintenance)

Basic philosophy Allow machinery to run to failure. Repair or replace damaged equipment when obvious problems occur.

This maintenance philosophy allows machinery to run to failure, providing for the repair or replacement of damaged equipment only when obvious problems occur.
The advantages of this approach are that it works well if equipment shutdowns do not affect production and if labor and material costs do not matter.

Preventive Maintenance (TBM)

Basic philosophy Schedule maintenance activities at predetermined time intervals. Repair or replace damaged equipment before obvious problems occur.

This philosophy entails the scheduling of maintenance activities at predetermined time intervals, where damaged equipment is repaired or replaced before obvious problems occur.
The advantages of this approach are that it works well for equipment that does not run continuously, and with personnel who have enough knowledge, skills, and time to perform the preventive maintenance work.

Predictive Maintenance (CBM)

Basic philosophy Schedule maintenance activities when mechanical or operational conditions warrant. Repair or replace damaged equipment before obvious problems occur.

This philosophy consists of scheduling maintenance when the condition gets to a predetermined unacceptable level, the equipment is shut down to repair or replace damaged components so as to prevent a more costly failure from occurring. In other words, Dont fix what is not broke.

Reliability Centered Maintenance (Pro-Active)

Basic philosophy Utilizes predictive/preventive maintenance techniques with root cause failure analysis to detect and pinpoint the precise problems, combined with advanced installation and repair techniques, including potential equipment redesign or modification to avoid or eliminate problems from occurring. This philosophy utilizes all of the previously discussed predictive/preventive maintenance techniques, in concert with root cause failure analysis. This not only detects and pinpoints precise problems that occur, but ensures that advanced installation and repair techniques are performed, including potential equipment redesign or modification, thus helping to avoid problems or keep them from occurring.

Other types of Maintenance

Corrective, which aims in restoring the defective item(s) to the required state.

Adaptive, which focus in adjusting a software product to properly interface with a changing environment. Perfective, which refers to enhancements to the product in order to either add new capabilities or modify existing functions.

Routine, which includes those maintenance activities that are repetitive and periodic in nature such as Routine inspections, cleaning, and small adjustment.
Legal, which refers to equipment which are subjected to rules or regulations by the government .

Comments and Questions

Thank you for your Attention

Please write your comments & feedback to sndopu@zesco.co.zm Samuel Ndopu