Maintenance

• Maintenance : Is a sequence of stages executed to hold machines

and equipment under good working conditions , Maintenance is profit
centre not cost centre
• Goals of Maintenance in Industry :-
- Reduce Maintenance labor and material cost
- Reduce Production loss
- Insure good performance of the machine
- Prevent any sudden Breakdown/Stop during useful lifetime of machine
- Renew machines
• Mechanical Reliability : It is the probability that a spare item or
machine will perform its prescribed duty without failure for a given
time when operated correctly in a specified Environment
• Maintainability : The ability to get a failed piece of equipment back
to its operating condition as soon as possible
• MTTR : Mean Time to Repair is the average time it takes to repair a
system , It includes repair time and any testing time. The clock doesn't
stop on this metric until the system is fully functional again.

• Non-Repairable System : is replaced with new item which will be as

good as the item replaced , Over time as items are replaced with
identical new items the failure rate will remain constant
• Repairable system : The Repaired item following a breakdown will
not be as good as when it was first installed. General wear and errors
in repair carried out will result in the failure rate increasing over time
• Availability : The probability that an item is performing its required
function at a given point in time. (Availability = Up Time / Total Time)
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• Selection of Good Maintenance Strategy Effect :-
- Maintenance Decreases MTTR so Increases Availability
- Maintenance Increases Efficiency so Increases Reliability
• Failure Modes : Are Equipment and component specific failures that
result in the functional failure of the system or subsystem
(Catastrophic Failure - Dominant Failure)
• Composition of Maintenance Organization :-
- Staff Engineers and Technicians
- Maintenance Systems
- Planning and Scheduling
- Spare Parts Management
• Forms of Maintenance and Strategies :-
- Corrective Maintenance
- Planned
- Unplanned
- Predictive Maintenance
- Condition Based (CBM): Relies on Condition Monitoring
- Scheduled Preventive : Relies on Historical Data and cost studies
• Types of Maintenance Systems : Simple - Sophisticated
• Simple Maintenance Department :-
- Maintenance Supervisor and Craftsmen
- No work order system
- Informal planning
- No preventive Maintenance
- Operates on a Run to Failure Policy
• Sophisticated Maintenance Department :-
- Work Order System
- Scheduled overhaul
- Formal planning and scheduling
- Detailed Scheduling of Jobs
- Detailed job costing system
- Time slotting Statistical standards
- Predictive-Diagnostic Maintenance
- Daily, work program and Failure analysis
- Excessive PM programs Work sampling program
• Structure of the Maintenance Department :-
A)Centralized Maintenance System
B)Decentralized Maintenance System
C)Combined (Centralized + De-Centralized) Maintenance System

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• Centralized Maintenance System
- Advantages
- Flexibility to Do the work
- Disadvantages
- Friction between Staff
- Excessive Feedback
- Increased Travel Time
• Decentralized Maintenance System
- Advantages
- Fast Response
- Reduced Travel Time
- High Level of knowledge of Equipment
- Disadvantages
- Poor Manpower Utilization
• Combined (Centralized + De-Centralized) Maintenance System
- All Advantages but expensive approach
- Works well for plants with extensive preventive maintenance programs
- Area maintenance responsible for predetermined preventive
maintenance load
- Central planning , control and caters for major breakdowns.
- Centralized warehouse with satellite area stock rooms
• Maintenance Department Staff
A) Maintenance Manager
B) Maintenance Foreman
C) Maintenance Planner
D) Maintenance Engineer

• Maintenance Manager Responsibilities :-

- To coordinate the maintenance scheduling with the plant and production
managers
- To design and approve the maintenance strategies and policies
- To approve the policy of inventory of spare parts and the maintenance
requirements
- To design and select training programs for all maintenance personnel
- To put in place and to ensure the sustainability of safety precautions
- To ensure Quality of purchases
- To follow up the Backlog control procedures
- To manage the implementation of software within the maintenance
department
- To develop therefore to manage the maintenance budget

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• Maintenance Foreman Responsibilities :-
- To Ensure the safety of his crew members, first by enforcing
implementation of the safety requirements and second by avoiding the
assignment of untrained staff to risky jobs
- To Motivate each and every one of his crew members
- To Evaluate the available skills
- Quality control
- Emergency planning
- Methods improvement
- Cooperation within fault and failure diagnosis
- Preparation and conductance of training programs
- Assign suitable craftsmen for jobs completion based on required skills
- General floor coordination and jobs follow-up
• Maintenance Planner Responsibilities :-
- To Estimate the requirements industrial site in terms of
- Man-hours per craft
- Workforce per craft
- Tools commissioning and replacement policy
- Spare parts
- To Review the lead times and their relation to the real life situation,
therefore to update the corresponding plans
- To Develop and to apply time slotting standards
- To Monitor, to record and therefore to analyze backlogs for each craft.
- To Assist in weekly scheduling meetings
- To Capture therefore to record relevant historical data
- Reviews breakdowns data in order to specify weakest area
- To Compare the planned time to the actual time of jobs completion
therefore to update the plans
- Contributes heavily in designing the preventive maintenance program as
well as inspection and diagnostics routines
• Maintenance Engineer Responsibilities :-
- To Assist in developing PM programs, inspection and fault diagnosis
routines, specifically by advising on the critical spots that should be
addressed
- To Conduct complicated and/or specialised diagnostic inspections and
examination
- To Contribute to focus teams in order to identify weakest areas and
causes of repetitive failures
- To Recommend therefore to conduct design-out maintenance for
equipment (alteration of the machine design)
- To Ensure the maintainability of new equipment before commissioning
- To be intimately familiar with maintenance budget and economic goals
- To Help within the long term planning process

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• Elaboration on Planning :-
- If the work is done with less people, how is the rest well employed ?
- It is not in the favor of the organization to use planners as standby
engineers
- The job of planning got to be ONLY future work
- Planners satisfy their knowledge through feedback
- Component level planning
- Computers do not make plans
- The personal expertise of planner contribute to the structure of the plan
- The Act o f measuring the time efficiency of the craftsmen while
performing the job is preferably performed through measuring wasted
time , Therefore expected times for jobs completion may be planned

• Run To Failure Maintenance (RTF) : It’s the Simplest Maintenance

strategy , In this strategy , Assets allowed to operate until they breakdown
- It is important to have spare parts & staff on hand to replace the failed part
and to maintain equipment availability
- This Strategy is useful for assets that on breakdown : No Safety Risks - Have
Minimal Effect on Production
• RTF Triggers : Asset breakdown is the only trigger used in RTF , If the
asset is not working, then maintenance is required
• RTF Advantages :-
- Minimal Planning : Since Maintenance doesn’t need scheduling in advance
- Easy to Understand : Because of the plan’s simplicity , this system is easy to
understand and implement
• RTF Disadvantages :-
- Unpredictable
- Costly : All costs associated with this strategy need to be considered when it is
implemented
- Inventory
• RTF Maintenance Task : Unplanned Reactive Maintenance is the only type
of maintenance task used for the run-to-failure maintenance strategy
• Appropriate Applications for Run to Failure Maintenance
- Run to Failure Maintenance makes sense when the total cost of repairing equipment
after breakdown is less than the cost of performing other types of maintenance
- Run to fail maintenance requires an understanding of how a machine might break
and what the consequences of breakdown are
- Run-to-failure would also be more appropriate for redundant or Non-Critical assets
• Inappropriate Applications for Run to Failure Maintenance
- Run to Failure Maintenance is unsuitable for applications where equipment failure
creates a safety risk
- Where equipment availability is necessary

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• Breakdown Maintenance : It is maintenance performed on
a piece of equipment that has broken down, faulted, or
otherwise cannot be operated , The goal of this maintenance
is to fix something that has malfunctioned
• Types of Breakdown Maintenance :-
- Planned Breakdown Maintenance : It Means
that the organization is prepared for a breakdown
and even expects it to happen
- Unplanned Breakdown Maintenance : Occurs when a piece of
equipment fails or breaks unexpectedly , also called an
unplanned downtime event
• Cases in which Breakdown Maintenance is
Applicable :-
- Equipment can’t be repaired at all (inaccessible - designed
to not be repaired)
- Asset consists of inexpensive or easy-to-replace parts
- Non-critical pieces of equipment (like hand tools)
- Objects/equipment that are disposable or meant to be
replaced at the end of their lifespan
- Short-life assets (Batteries)
• Advantages of Reactive Maintenance :-
- It takes less Time and Money
- No initial costs associated with Reactive Maintenance
- It Requires less Planning than Preventive Maintenance
• Disadvantages of Reactive Maintenance :-
- More Expensive
- Shorter Asset Life Expectancy
- Safety issues
- Inefficient use of time
- Bad for Backlog
- Higher Energy Costs

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- More Expensive : Unexpected downtime during production
runs can result in late orders, damaged reputations and impacted
revenue. On top of that, the unpredictable nature of reactive
maintenance means that labour and spare parts may not be
readily available so organizations can end up paying a premium
for emergency parts shipping, travel time, and after-hours
support

- Shorter Asset Life Expectancy : Reactive maintenance does

not keep systems running in optimal “as new” condition. In a lot
of cases, you’re doing just enough to get a machine up and
running again, and over time, systems that have been patched
again and again deteriorate faster and don’t maximize their initial
capital cost investment

- Safety issues : When work is scheduled, technicians have time

to review the standard procedures and safety requirements to
complete the job correctly. Technicians tend to take more risks
when maintenance work is reactive because they’re under
pressure to get systems running without delay

- Inefficient use of time : While planned maintenance can be

included in a production schedule, reactive maintenance tends to
catch you unawares, and technicians spend time running around
looking for the correct manuals and schematics, ordering the
right parts and trying to diagnose and fix the issue

- Bad for Backlog : Emergency repairs are usually prioritized at

the expense of planned work, which may be pushed or cancelled
completely. This can lead to maintenance backlog which is really
hard to get on top of once it starts to pile up

- Higher Energy Costs : When equipment is not properly

maintained, it uses more energy. Doing simple things like
greasing moving parts or changing filters can reduce energy
consumption by 15%

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• Preventive Maintenance : it is Maintenance that is regularly action
performed on equipment to lessen the likelihood of it failing
• Scheduled Preventive Maintenance : It is performed while the
equipment is still working so that it does not break down unexpectedly
- Routine Inspections
- Routine Adjustments
- Routine Calibrations
- Cleaning
- Scheduled replacements of parts
• Types of Preventive Maintenance (Triggers)
- Time-Based : (Ex : Regular inspection on a critical piece of equipment
that would severely impact production in the event of a breakdown)
- Usage-Based : Usage-based triggers fire after a certain amount of
kilometers, hours, or production cycles. (Ex : Motor which might be
scheduled for service every 10,000km)
• Suitable Preventive Maintenance Applications
- Assets That Have a critical operational function
- Assets That Have failure modes that can be prevented (and not
increased) with regular maintenance
- Assets That Have a rate of failure that increases with time or use
• Unsuitable Preventive Maintenance Applications
- Assets That Have random failures that are unrelated to Maintenance
- Assets That Do not serve a Critical Function
• Planning Preventive Maintenance without the help of CMMS
software can be a huge challenge :-
- Since PMs are triggered after a certain amount of time or use, it’s
difficult (if not near impossible) to track that data manually,
especially if you’re dealing with many pieces of critical equipment
- Maintenance software allows you to set PMs according to the
triggers that are appropriate for each piece of equipment. Once the
trigger occurs, a work order will be created
- Maintenance software allows organizations to gather data
surrounding PM activities to report on or optimize those activities,
and set maintenance KPI’s (Key performance indicators) to work
towards

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• Advantages of PM compared with Less Complex Strategy
- Planning : Unplanned , reactive maintenance has many costs that can be
avoided during the planning process. The cost of unplanned maintenance
includes lost production, higher costs for parts and shipping, as well as time lost
responding to emergencies and diagnosing faults while equipment is not
working. Unplanned maintenance typically costs three to nine times more than
planned maintenance When maintenance is planned, each of these costs can
be reduced
- Equipment can be shut down : To coincide with production downtime
- Decrease the Total Cost of the Maintenance
- Safety : is improved because equipment breaks down less often than in less
complex strategies
• Advantages of PM compared with More Complex Strategy
- Doesn’t Require Condition-Based Monitoring : This Eliminates the need
(and cost) to conduct and interpret condition monitoring data and act on the
results of that interpretation
- Eliminates the need Condition Monitoring Equipment
• Disadvantages of PM compared with Less Complex Strategy
- Unlike Reactive Maintenance , Preventive Maintenance requires
maintenance planning. This requires an investment in time and resources
that isn’t required with less complex maintenance strategies
- Maintenance may occur too often with a preventive maintenance
program , Unless maintenance frequencies are optimized for minimum
maintenance , too much or too little preventive maintenance will occur
• Disadvantages of PM compared with More Complex Strategy
- The Frequency of Preventive Maintenance is most likely to be too high
- This Frequency can be lowered, without sacrificing reliability when
condition monitoring and analysis is used. The decrease in maintenance
frequency is offset by the additional costs associated with conducting
the condition monitoring

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• Predictive Maintenance : It’s a technique uses condition-monitoring
tools and techniques to track performance of equipment during normal
operation to detect possible defects & fix them before they result in failure
- Ideally , Predictive Maintenance allows the maintenance frequency to be
as low as possible to prevent unplanned reactive maintenance, without
incurring costs associated with doing too much preventive maintenance
• How does Predictive Maintenance Work ?
- Predictive maintenance uses Condition-Monitoring Equipment to
evaluate an asset’s performance in real-time. A key element in this
process is the Internet of Things (IoT) , IoT allows Assets & Systems
to connect, work together, share, analyze and action data
- Choosing the correct technique for performing condition monitoring is
an important consideration that’s done in consultation with equipment
manufacturers and condition monitoring experts
• Condition-Based Maintenance Practices like Vibration
Analysis rely on the Fact that :
- Many Failures develop over a period of time
- It’s Possible to take action to Prevent Failure & Avoid Consequences
• To Prevent Functional Failure : Depending on failure mechanism ,
it is sometimes possible to intervene to repair the existing component
before it fails completely
• To Avoid Consequences of the Failure : Detecting a potential
failure doesn’t actually prevent the spare from failing , but still makes
it possible to avoid or reduce the consequences of the failure

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• Operating Parameters :-
- Vibration
- It’s the Best Operating Parameter to judge rotating machinery conditions such
as (balance, alignment, bearing stability, and stress applied to components)
- Measuring the overall vibration of Machine , Rotor in relation to a machine or
Structure of a machine , and comparing the measurement to its normal value
(baseline reading) and alarm set points , indicates current health of machine
- Temperature
- Temperature Measurement (Thermograph) is a useful indicator of Electrical
or Mechanical Condition
- Such as The Load Applied to Thrust Bearing, As Bearing Fails , Friction
Causes it’s temperature to rise , The use of infrared cameras or installing
thermocouple sensors in the housing of a bearing and measuring
temperature changes within the bearing or lubricant allows problems to be
recognized early
- Lubricating Oil Analysis
- Monitoring Oil condition warns of an increase in foreign substances, such as
water, which can degrade the lubricating properties of the oil and cause
bearing failures
- It detects the presence of metallic particles carried into the oil stream . These
metallic particles are analyzed to determine which part of the machine is
wearing and how fast. Particle
- Counting & Ferro-Graph are two analysis techniques
- Acoustics
- Very High Frequency , Acoustically Transmitted Vibration is measured with a
high Frequency Piezoelectric Sensor
- This Sensor is excited by compression waves produced by metal-to-metal
contact and by metal as it mechanically fails
- The Acoustic Flow detection signal is conditioned to produce outputs, which
can be measured as numerical values on Ammeter , These measurements
are used to judge the overall condition of a bearing and evaluate local defects
, This Technique is highly effective in very early detection of bearing failure
- The Human Senses
- The simplest condition monitoring techniques are the four human senses
(look, listen, feel, and smell) Machinery faults such as:
- Visible wear on slides
- Vibration levels from rotating equipment
- Damage on conveyor belts, drive belts.
- Tension adjustment on belts, drive chains.
- Oil and Water levels
- Pressure and other types of gauges can be monitored
- Heat build-up on bearing housings refractory Linings
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• Benefits of Predictive Maintenance :-
- When predictive maintenance is working Effectively , Maintenance is only
performed on machines when it is required . That is just before failure is
likely to occur , This brings several cost savings
- Minimizing the time the equipment is being maintained
- Minimizing the production hours lost to maintenance
- Minimizing the cost of spare parts and supplies
- Predictive maintenance programs have been shown to lead to a
- 25%-30% reduction in maintenance costs
- 70%-75% decrease of breakdowns
- 35%-45% reduction in downtime.
- These cost savings come at a price , Some condition monitoring techniques
are expensive and require specialist and experienced personnel for data
analysis to be effective
• Advantages of Predictive Maintenance :-
- Compared to Preventive Maintenance , Predictive maintenance ensures
that equipment requiring maintenance is only shut down right before
failure . This reduces total time & cost spent maintaining equipment
- Reduce the need of spare parts
• Disadvantages of Predictive Maintenance :-
- Compared with preventive maintenance, the cost of the condition
monitoring equipment needed for predictive maintenance is often high
- Skill & experience required to analyze condition monitoring data is high
- These can mean that condition monitoring has a high upfront cost
- Not all assets have failures that may be more Cost-Effectively maintained
using preventive maintenance or a Run-to-Failure maintenance strategy
- Judgment should be exercised when deciding if predictive maintenance
is best for particular asset
• Suitable Applications for Predictive Maintenance :-
- Assets that have a critical operational function
- Assets that have Failure modes that can be Cost-Effectively predicted
with regular monitoring
• Unsuitable Applications for Predictive Maintenance :-
- Assets that Don’t serve a critical function
- Assets Doesn’t have Failure mode that can be cost-effectively predicted

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• Vibration of Machines : Vibration is a result of dynamic forces of
machine which have moving parts connected to it
- Different parts of Machine will vibrate with various frequencies &
amplitudes
- Vibration Causes Wear & Fatigue , That’s often responsible for the
breakdown of the machine

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• Vibration Transducers : It convert mechanical motion (vibration ) into a
dynamic (AC) electrical signal
- It Requires amplification and/or conversion electronics to produce an
output signal with sufficient strength for transmission and use by
monitoring, display, analysis, and recording instrumentation (measuring
chain)
- Vibration transducers used for machine condition monitoring include:
- Non-contact displacement transducer (Eddy current probe)
- Velocity pickup (Electromechanical and Piezoelectric)
- Mechanical Levers : Measures Displacement
- Accelerometers (Piezoelectric)
- Piezoelectric Accelerometers are most common used
acceleration transducer : A typical piezoelectric acceleration
transducer contains one or more piezoelectric crystal elements,
which may be either natural materials, such as quartz, or man-
made. The crystal element is preloaded by a mass, and the
entire assembly is enclosed in a rugged protective housing

• Noise Measuring Equipment

- Measuring Condenser Microphone
- Microphone Measurement Range
- The reason for it’s acceptance is that condenser microphone has following properties
- High stability under various environmental conditions
- Flat frequency response over a wide frequency range
- Low distortion
- Very Low internal noise
- Wide dynamic range
- High Sensitivity

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• Total Productive Maintenance : TPM is a strategy that
operates according to the idea that everyone in a facility
should participate in maintenance, rather than just the
maintenance team
- This Approach uses the skills of all employees and seeks to
incorporate maintenance into the everyday performance of a
facility
- Everyone from top-level management to equipment operators
should participate in maintenance , Each member of an
organization can contribute in their own way:
- Top Management Engineers : Management should be involved in TPM by
promoting it as a corporate policy
- Reliability Engineers : Need to be involved , They can interpret the
maintenance data stored in organization’s CMMS to find relevant metrics &
generate business insights
- Operators : Are the owners of a facility’s assets, meaning they need to take
responsibility for the day- to-day maintenance of their machines. This
includes the cleaning and regular lubrication necessary for equipment health.
Operators are also expected to find early signs of equipment deterioration
and report them, as well as determine ways to improve equipment operation
- Maintenance Managers & Technicians : Are expected to train and support
operators to meet their goals and perform more advanced preventive
maintenance activities. They are also expected to take responsibility for
improvement activities that will impact the key performance indicators (KPIs)
set out by reliability engineers
• Advantages of TPM :-
- Fewer Breakdowns : When machine operators keep an eye out for
changes with their equipment, big issues are more likely to be spotted early,
before a breakdown occurs. This lets the maintenance team get on top of their
PM maintenance schedule, rather than always reacting to emergency
breakdowns
- Safer Workplace : Technicians are much more likely to take risks when
rushing to fix a breakdown, so fewer breakdowns generally mean a safer
workplace. On top of that, when everyone keeps maintenance in mind,
problems can be spotted and dealt with well before they become potentially
dangerous situations
- Better overall performance : If everyone in a facility is keeping eye on
maintenance, small fixes will stop going undetected, which helps you move
away from reactive maintenance and get backlog under control. It takes the
pressure of small jobs off the maintenance team so they can concentrate on the
bigger jobs, which increases the overall performance of your facility

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• Reliability Centered Maintenance : RCM is a corporate-
level maintenance strategy that is implemented to optimize the
maintenance program of a company or facility
- The Final result of an RCM program is the implementation of a
specific maintenance strategy on each of the assets of the facility
- The Maintenance strategies are optimized so that the productivity of
the plant is maintained using cost-effective maintenance techniques
- 4 Principles that are critical for a RCM Program :
- The Primary objective is to preserve system function
- Identify failure modes that can affect the system function
- Prioritize the failure modes
- Select applicable and effective tasks to control the failure modes
• Advantages of RCM : Implementing RCM increases
equipment availability, and reduces maintenance and resource
costs. Jardine and Tsang give an example of a utility company
who reduced maintenance costs by up to 40%
• Disadvantages of RCM : RCM doesn’t consider the total cost of
owning and maintaining an asset. Additional costs of ownership, like
those considered in evidence-based maintenance, are not taken into
account, and aren’t factored into the maintenance considerations
• Reliability Centered Maintenance
- Reactive
- Small items
- Non-critical
- Inconsequential
- Unlikely to fail
- Redundant
- Preventive
- Subiect to Wear-Out
- Consumable Replacement
- Failure Pattern Known
- Predictive
- Random failure patterns
- Not subject to wear
- PM induced failures
- Proactive
- RCFA
- Age Exploration
- FMEA

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• Aim of the Spare Parts Management : Achievement of Balance
between: Unavailability of spare parts & Over-Storage
• Spare Parts Requirements :-
- Corrective jobs with different priorities
- Preventive maintenance schedules
- Predictive maintenance schedules
• Effective spare parts management plays a critical role to keeps
the operation running And reducing MTTR
• Spare Parts and Inventory Management Problems :-
- Lead Time : Time between placement and receipt of an order
- Uncertainty in demand
- Coding and numbering
- Costing
- Safety
- Excessive storage
- Stockout
• Inventory Value : Total value of spare parts stored varies with time
• Initial Inventory Value (Io) : It’s maximum level of inventory value
at the time the order is received
• Average Inventory Value (Ive) : It’s half of Initial Inventory Value
if uniform orders are placed
• Ordering Cost (Procurement Cost) : Refers to the salaries paid to
the staff of the purchasing department , stationery expenses, cost of
accounting and administrative work incurred because of purchase orders,
office rental and lighting/air-conditioning , transportation of
spare parts, costs incurred in receiving and inspecting the
spare parts , etc
• Carrying Cost (Holding Cost) : Refers to the rental of store, costs
of lighting and air- conditioning, costs incurred in stock-
keeping & security, interest on the lock-up investment capital
in inventory purchasing, costs due to spare parts
deterioration, depreciation & insurance
• Economic Order Quantity (EOQ) : It’s the
quantity which should be purchased in an order (Io)
such that the overall inventory cost would be minimized
Total Inventor y Cost = Ordering Cost + Carr ying Cost
Total S . P Cost = Initial Cost + Inventor y Cost Per Par t
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• Efficacy : Is the capacity of producing the desired result
Efficiency : How Well you use your Resources (Time)
Effectiveness : How Well you get to your Objectives (Quality & Time)
• Craft Performance (CP) : It’s the key element affecting Overall
Craft Effectiveness , It Shows how efficient we are in actually doing
hands-on craft work when compared to established planned time or
performance standard
Total Planned Time (Hours)
CP % = × 100
Total Actual Cra f t Hours Required

• Methods for Establishing planning times for Maintenance :-

- Reasonable Estimates
- Historical Data : The results of past experience are captured via the CMMS or
other means to get average times to do a specific task
- Predetermined Standard Data : Standard data tables for a wide range of
small maintenance tasks have been developed
• Maintenance management uses planning as a tool to reduce
unnecessary job delays through advance preparation by
Preparing the work plan
• Work Plan : Work plan is the assembled information that the planner
makes ready for the technician who will later execute the work
• The Planning Mission : The Mission of planning revolves around
making the right jobs ready to go to increase labor productivity
• Planning Principles :-
1) Planners are organized into Separate department from the maintenance craft
crews to :
- Facilitate specializing in planning techniques
- Focus on Future work
2) Planning Department concentrates on future work that has not been started
- in order to provide the Maintenance Department at least one week of work
backlog that is planned , approved, and ready to execute
- This backlog allows crews to work primarily on planned work
3) The Planning Department maintains a simple, secure file system based on
equipment tag numbers
- The File system enables planners to utilize equipment data and information
learned on previous work to prepare and Improve work plans , especially on
repetitive maintenance tasks
- File cost information assists making repair or replace decisions
- Supervisors and plant engineers are trained to access these files to gather
information they need with minimal planner assistance

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 4) Planners use experience and file information to develop work plans
- As a minimum. planners are experienced, top level technicians that are trained in
planning techniques
5) The Planning Department , Recognizes the skill of the crafts ,
- The planner responsibility is “What” and craft technician's responsibility is “How”
6) Wrench Time is the primary measure of work force efficiency and of planning
& scheduling effectiveness
• Work Order (Work Request) :-
- Work orders should be initiated by anyone desiring work to be done
- Appropriate approvals are required depending on the nature of the work
requested
• Work Order Dispatching (Maintenance Department) Procedures
- Determining what Manpower , Materials , Equipment and Special Tools
which are required to complete the work
- Determining what sequence of activities must occur (Maintenance and
troubles catalogue)
- Coordination with other organizational entities is required
• Work Order Form and Required Fields :-
1) An Identified problem , need or Work Request
2) The Work authorized to be done
3) The Plans , details, and schedules necessary to perform the work
4) The Results of that work
- After work completion, the planning department files work order forms
which have historical value to assist future work
• Planning Procedures :-
1) Determination of the Craft Skill Level
2) Estimating the Time Required
3) Estimating the Parts Required
4) Determination of the special Tools Required
5) Determination of Confined Space & Job Safety
6) Crew executes the job and provides feed back
7) Actual field cost after execution
• Job Safety : For each special safety concern , The Planner
describes the necessary safety issues
• Confined Space : A Confined space is an area with a potentially
dangerous environment regarding respiration
• Labor Cost = (Salary Rate/Hour) x (Hours Required for Task)
• Production Losses = (Production Losses/Hour) x (Fixing Time)
• Repair Cost = Spare Part Cost + Labors Cost
• Fault Cost = Production Losses + Repair Cost

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• Maintenance Scheduling : It is the process of making sure planned
work is carried out. It involves bringing all the necessary resources
together to make sure tasks are completed correctly and on time
• Elements of Scheduling (Principles of Scheduling) :-
1) Job Plans Providing :
- Number of persons required
- Lowest required craft skill Level
- Craft work hours per skill level
- Job duration
2) Weekly and Daily Schedules must be adhered to as closely as possible
- Proper priorities must be placed on new work orders to prevent interruption
of these schedules
3) A Scheduler develops a one week schedule for each Crew based on:
- Craft Hours available
- Forecast that show highest skill level available
- Job priorities
- Information from job plans.
- Multiple jobs on the same Equipment or system
4) The One Week Schedule assigns work for every available Work Hour
- The schedule allows for : Emergencies - High Priority - Reactive Jobs
5) The Crew Supervisor develops daily schedule 1 day in advance using
guide :
- Current job progress,
- The one week schedule
- Reactive jobs
6) Wrench time Is the primary Measure of work force efficiency and of
planning and scheduling Effectiveness
• Scheduling Procedures :-
1) Forecasting Work Hours
2) Sorting Work Orders
A) By Work Order Number
B) By Priority of the Required Work
C) By the Same System and Area
3) Allocating Work Orders
4) Assigning Names
• Job Duration : Total Number of Hours Required for Job
• Work Hours : No. Of Hours/Day x No. of Days x No. of Engineers
- Note : One Helper can help multiple Engineers in the same time
- EX : Job needs 10 Hrs/Day , Need 2 Eng 1 Helper , 2 Days -> JD:20 / WH:60

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• Information Systems : Are the application programs and databases
used by planners and management to carry out and control (manage)
their jobs
• Component Tracking : Components that rotate from one equipment
unit to another should be tracked by serial number. In this way, a
complete history of the number of hours it operated and the work
performed on each component unit can be maintained
• Failure Analysis and Warranty Control : Failure analysis is used
primarily to determine causes of recurring equipment or component
failures and to identify methods of avoiding future failures. Therefore,
a useful tracking system should also document failure analysis
• Work History and Costs : Recording maintenance history on a daily
basis is an important aspect of managing the maintenance effort.
Control is most effective when equipment repair history is available
for reference. Noticeable trends within a unit’s repair history can
assist in identifying and solving specific problems
• MMIS : Maintenance Management Information System
• CMMS : Computerized Maintenance Management System
- Improved Productivity : Giving reduced direct labour costs
- Increased Equipment Availability : Due to better planning
- Increased Equipment Reliability : Through identification of repetitive faults
- Improved Stock Control : Giving Reduced inventory levels & less stockout
- Improved Safety : By providing detailed Standard job procedures
- Ability to create a work order and automatically post it on the backlog

- Dynamic scheduling of work from Backlog for a specific date & shift
- Automatic maintenance of the Backlog , Jobs are removed automatically
when work orders are completed
- Ability to Retain a work history of Equipment , components and tires
- Ability to Retain a history of the Costs and Man-Hours
- Dynamic creation of a weekly forecast from the backlog that shows the
effect on manpower distribution
- Automatic scheduling of PM services based on calendar day, operating
hours, operating tons, or week of the years
- The Ability to track purchase orders associated with each work order
- The Ability to create PM checklists
- The Ability to monitor equipment availability and utilization
- The Ability to provide job standard
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• Elements of Maintenance Management Information System and Work Control

Work Work
Work Planning
Identification Scheduling

History Work
Analysis
Recording Execution

• CMMS in Recording and Analyzing Provides the Following :-

- The Number of Failures
- The Root Causes of those Failures
- The Maintenance Costs associated with those Failures
- The Production Costs Associated with those Failures
- Any Safety or Environmental implications associated with those Failures
• The Outputs of CMMS :-
- Work Orders
- Contractors Work Order From a Job or List
- Time Card Module
- PM Routines and Equipment Information Reports
- Inventory and Purchasing
- Performance Reporting
• Maintenance Spare Parts and Inventory Control :-
- Determination of the Required Spare Parts
- Determination of the Minimum Stock Level
- Prevent the Stockout
- Prevent the Excess Store Level

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• The Maintenance Operation Audit Includes:-
- Measures Maintenance Personnel's compliance to Preventive and
predictive maintenance programs
- Management Compliance to Maintenance Operation Procedures
- Inventory Management Compliance to process flow and procedure
- Finances / Budget in compliance to the budgeting process
- Contractor Performance and procedures compliance
- Regulatory compliance to inspection frequency and regulated requirements
- Maintenance personnel compliance with the CMMS Convention and QA
- Plant Shutdown / Turnaround procedure compliance
- Technical publications in compliance to maintenance operation procedures
- Reliability team in compliance to maintenance operation procedures
- Maintenance Performance Evaluations are executed
• The Maintenance Plan Audit Includes:-
- Benchmarking References are Maintained
- WorkOrders QA
- Equipment Failure History Accuracy
- Equipment Records (for Accuracy)
- Equipment Life-Cycle Profile Tracking UP-Date
- Failure and Root Cause Analysis Practice and Compliance
- Equipment Maintenance Plan Compliance
- Equipment Spare Parts Rationalization Compliance
- Maintenance Improvement in compliance with the Reliability
Improvement Plan
- Asset Performance Evaluation Monitoring is in compliance with
specifications
• Benefits From an Audit :-
1) Documentation of the strengths and opportunities for improvement complete
with a plan Forward
- The Audit report allows you to target areas of opportunity without Re-Engineering
- Provides valuable insight allowing you to better plan your budget
- Provides valuable information to justify improvement project funding and
budgeting
- Provides information to project future costs
2) Documents your present maintenance process effectiveness in terms of how
well it is able to achieve your maintenance goals
- Provides a practical tool to further improve maintenance program cost
effectiveness
- Provides valuable information to compare your operation with other operations
- Provides a tool for budget justification
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 3) Compare Present Maintenance program against physical condition of plant
- Provides a tool with which to better prioritize maintenance decisions
- Provides a tool to justify management decisions
- Provides an opportunity to improve your present operation
4) Delivers a Plan Forward Complete with Recommendations and Conclusions
- Recommend identified enhancements that will reduce maintenance costs and
improve reliability
- Deliver a path forward based on existing strengths and your company's tolerance
for improvements
• Key Maintenance Metrics Performance Measurement :-
• Facilities Maintenance Management Metrics :-
1) Facility Condition Metrics
A) Annual Maintenance Funding ($) : Should be between 2% ~ 4%
B) Current Replacement Value of Assets ($)
2) Work Performance Metrics
A) Emergency Trouble Call Response (Hours) : Should Show a Downward trend
B) Emergency Trouble Call Completion (Hrs) : Should Show a Downward trend
Jo b s Co m pl e t e d a s Sch e d u l e d (N u m b e r)
C) : Should be 100%
To t a l Jo b s Sch e d u l e d (N u m b e r)

3) Effect of Condition-Based Maintenance Metrics : The Following metrics should

develop a negative trend as the maintenance program shifts from reactive and time-
based maintenance to condition-based maintenance
P r o g r a m m e d M a i n t e n a n c e ($)
A) T o t a l M a i n t e n a n c e C o s t ($)
: Should be 60%
R e p a i r C o s t ($)
B) T o t a l M a i n t e n a n c e C o s t ($)
: Should be 30%
T r o u b l e C a l l s ($)
C) T o t a l M a i n t e n a n c e C o s t ($)
: Should be 10%
S e r v i c e R e q u e s t s ($)
D) T o t a l M a i n t e n a n c e C o s t ($)
: Should be 0% ~ 5%
R e p l a c e m e n t o f O b s o l e t e I t e m s ($)
E) T o t a l M a i n t e n a n c e C o s t ($)
: Should be 15% ~ 20% , Should show Upward Trend

4) RCM Performance Metrics

A) Equipment Availability
H o u r s Ea c h U n i t o f Eq u i p m e n t i s Av a i l a b l e t o R u n a t C a p a c i t y
Tot a l Hour s Dur i ng th e Repor t i ng T i m e Per io d
: Should be 96%

B) Maintenance Overtime Percentage

Tot a l Mai n t en a n ce O ver t i m e Hour s Dur i ng th e Per io d
Tot a l Regu l a r Ma i n t e n a n ce Hour s D ur i n g th e Per i o d
: Should be 5% or Less
C)Emergency Percentage
T o t a l Ho u r s Wo r k e d o n E m e r g e n c y Jo b s
T o t a l Ho u r s Wo r k e d
: Should be 10% or Less
4) Budget Execution Metrics
A) Equipment Availability , P r i o r Y e a r E x e c u t i o n ($)
P r i o r Y e a r B u d g e t ($)
: Should be 100%

B) Maintenance Overtime Percentage , C u r r e n t Y e a r E x p e n d i t u r e s t o D a t e ($)

C u r r e n t Y e a r B u d g e t t o D a t e ($)
: Should be 100%

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