maintenance managementosp.mans.edu.eg/elbeltagi/fac 4-maintenane management.pdf · planning,...

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16/11/2016 Emad Elbeltagi 1

Maintenance ManagementMaintenance Management


Definition

Current Practices

Types of Failures

Maintenance Strategies

Types of Maintenance

Repair and Maintenance

Definition

Current Practices

Types of Failures

Maintenance Strategies

Types of Maintenance

Repair and Maintenance

AgendaAgenda

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DefinitionDefinition

Maintenance is the routine and recurring process of keeping a particular asset in its normal condition so that it can deliver the excepted performance or service without any loss or damage

Maintenance is the routine and recurring process of keeping a particular asset in its normal condition so that it can deliver the excepted performance or service without any loss or damage


DefinitionDefinition

Maintenance Management all the activities that determine the maintenance objectives, strategies and implementation by means of maintenance planning, control, supervision and considering economical aspects

Maintenance Management all the activities that determine the maintenance objectives, strategies and implementation by means of maintenance planning, control, supervision and considering economical aspects

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Current PracticeCurrent Practice

Maintenance is the actions associated with facilities after it is broken

While maintenance should be actions taken to prevent a facility from failing or to repair normal degradation to keep it in proper working order

However, data obtained in many studies indicates that facilities’ owners do not expend the necessary resources to make maintenance in proper working order

Maintenance is the actions associated with facilities after it is broken

While maintenance should be actions taken to prevent a facility from failing or to repair normal degradation to keep it in proper working order

However, data obtained in many studies indicates that facilities’ owners do not expend the necessary resources to make maintenance in proper working order


Current PracticeCurrent Practice

Rather, they wait for the failure to occur and then take whatever actions are necessary to repair or replace the facility

Nothing lasts forever and all facilities have predefined life expectancy or operational life

For example, equipment may be designed to operate at full design load for 5,000 hours and may be designed to go through 15,000 start and stop cycles

Rather, they wait for the failure to occur and then take whatever actions are necessary to repair or replace the facility

Nothing lasts forever and all facilities have predefined life expectancy or operational life

For example, equipment may be designed to operate at full design load for 5,000 hours and may be designed to go through 15,000 start and stop cycles

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FailuresFailures

Failure – inability to produce work in appropriate manner

Equipment / machine failure on production, failure of power supply, air-conditioned system, computer network, photocopy machine

Vehicle failure – brake, transmission, engine, cooling system

Building, bridge, road failure, etc.

Failure – inability to produce work in appropriate manner

Equipment / machine failure on production, failure of power supply, air-conditioned system, computer network, photocopy machine

Vehicle failure – brake, transmission, engine, cooling system

Building, bridge, road failure, etc.


Types of FailuresTypes of Failures

Failures can be grouped into three categories, understanding these is critical when assigning maintenance tasks: Induced

Intermittent

Wear out

Failures can be grouped into three categories, understanding these is critical when assigning maintenance tasks: Induced

Intermittent

Wear out

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Types of Failure (Induced)Types of Failure (Induced)

Induced failures are a result of an outside force causing the failure mode

For instance, extra loads on a given structure

Monitoring may help detect these potential failures

Failure must be recognized and analysis performed to determine the root cause

As such, we acting proactively and making the transition into a Reliability-Based Maintenance

Induced failures are a result of an outside force causing the failure mode

For instance, extra loads on a given structure

Monitoring may help detect these potential failures

Failure must be recognized and analysis performed to determine the root cause

As such, we acting proactively and making the transition into a Reliability-Based Maintenance


Types of Failure (Intermittent)Types of Failure (Intermittent)

Intermittent failures can happen at any time "random” , time between failures cannot be determined

Failures can best detect through process and predictive maintenance monitoring

Many plants find that preventive maintenance are not effective in determining the onset of failure in either induced or intermittent failures and, therefore, a waste of capital

Intermittent failures can happen at any time "random” , time between failures cannot be determined

Failures can best detect through process and predictive maintenance monitoring

Many plants find that preventive maintenance are not effective in determining the onset of failure in either induced or intermittent failures and, therefore, a waste of capital

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Types of Failure (Wear Out)Types of Failure (Wear Out)

Wear-out failures have a known time between failures and they occur when the useful life of a component is expended

These types of failure modes are often detectable through process and predictive maintenance monitoring

However, time-based refurbishment usually proves to be the most effective maintenance strategy

Wear-out failures have a known time between failures and they occur when the useful life of a component is expended

These types of failure modes are often detectable through process and predictive maintenance monitoring

However, time-based refurbishment usually proves to be the most effective maintenance strategy


Failure Against Life CycleFailure Against Life Cycle

The failure rate against a facility life cycle can be represented as follow:

The failure rate against a facility life cycle can be represented as follow:

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The initial period of the curve is characterized by high failure rate which may be linked to poor design, poor installation, or misapplication

The infant mortality period is followed by a nearly constant failure rate period known as useful life

There are many theories on why components fail in this region, most acknowledge that poor O&M often plays significant role

The initial period of the curve is characterized by high failure rate which may be linked to poor design, poor installation, or misapplication

The infant mortality period is followed by a nearly constant failure rate period known as useful life

There are many theories on why components fail in this region, most acknowledge 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

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

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Maintenance in Service IndustryMaintenance in Service Industry

Hospital

Restaurants

Transport companies

Banks

Hotels and resorts

Shopping malls / retail

Gas station

Hospital

Restaurants

Transport companies

Banks

Hotels and resorts

Shopping malls / retail

Gas station


Questions?Questions?

Why do we need maintenance?

What are the costs of doing maintenance?

What are the costs of not doing maintenance?

What are the benefits of maintenance?

How can maintenance increase profitability of company?

Why do we need maintenance?

What are the costs of doing maintenance?

What are the costs of not doing maintenance?

What are the benefits of maintenance?

How can maintenance increase profitability of company?

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Maintenance Objectives Maintenance Objectives

Ensure that facilities and their associated services are in a safe condition

Ensure that facilities are fit to use

Ensure that the condition of the facilities meets all statutory requirements

Maintain the value of facilities stock

Improve the quality of a facility

Ensure that facilities and their associated services are in a safe condition

Ensure that facilities are fit to use

Ensure that the condition of the facilities meets all statutory requirements

Maintain the value of facilities stock

Improve the quality of a facility


Maintenance StrategiesMaintenance Strategies

Maintenance can be divided into the following strategies: Reactive (day-to-day repair)

Preventive, which includes cyclic and condition-based maintenance

Predictive, modernization and maintenance which include additional works needed as a result of new legislation and regulations

Maintenance can be divided into the following strategies: Reactive (day-to-day repair)

Preventive, which includes cyclic and condition-based maintenance

Predictive, modernization and maintenance which include additional works needed as a result of new legislation and regulations

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Maintenance Strategies (Reactive)Maintenance Strategies (Reactive)

Reactive maintenance is basically the “run it till it breaks” maintenance mode

No actions or efforts are taken to maintain the facility to ensure design life is reached

Studies indicate this is still the predominant mode of maintenance in the United States, more than 55% of maintenance resources and activities of an average facility are still reactive

Emergency or nonplanned

Reactive maintenance is basically the “run it till it breaks” maintenance mode

No actions or efforts are taken to maintain the facility to ensure design life is reached

Studies indicate this is still the predominant mode of maintenance in the United States, more than 55% of maintenance resources and activities of an average facility are still reactive

Emergency or nonplanned



If our maintenance program is purely reactive, we will not expend manpower dollars, we could view this period as saving money

In reality, during the time, we are spending more dollars associated with capital cost because, while waiting for the facility to deteriorate, we are shortening the life of the facility resulting in more frequent replacement

If our maintenance program is purely reactive, we will not expend manpower dollars, we could view this period as saving money

In reality, during the time, we are spending more dollars associated with capital cost because, while waiting for the facility to deteriorate, we are shortening the life of the facility resulting in more frequent replacement

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Advantages Low cost

Less staff

Disadvantages Increased cost due to unplanned downtime of a facility

Cost involved with repair or replacement of components

Possible secondary damages from failure of main components

Inefficient use of staff resources

Advantages Low cost

Less staff

Disadvantages Increased cost due to unplanned downtime of a facility

Cost involved with repair or replacement of components

Possible secondary damages from failure of main components

Inefficient use of staff resources



Breakdown maintenance, in this system the facility is allowed to function / operate till no failure occurs; ie no maintenance work is carried out in advance to prevent the failure

As long as the facility is functioning at a minimum acceptable level, it is assumed to be effective

This approach is ineffective and extremely expensive due to: poor planning and incomplete repair

Breakdown maintenance, in this system the facility is allowed to function / operate till no failure occurs; ie no maintenance work is carried out in advance to prevent the failure

As long as the facility is functioning at a minimum acceptable level, it is assumed to be effective

This approach is ineffective and extremely expensive due to: poor planning and incomplete repair

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Preventive maintenance is a maintenance program committed to the elimination or prevention of corrective and breakdown maintenance

A comprehensive preventive maintenance program involves periodical evaluation of critical equipment to detect problems and schedule maintenance tasks to avoid degradation in operating conditions

Planned or scheduled

Preventive maintenance is a maintenance program committed to the elimination or prevention of corrective and breakdown maintenance

A comprehensive preventive maintenance program involves periodical evaluation of critical equipment to detect problems and schedule maintenance tasks to avoid degradation in operating conditions

Planned or scheduled

Maintenance Strategies (Preventive)Maintenance Strategies (Preventive)



Preventive maintenance defined as actions performed on a time or run-based schedule that detect 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

Expending the necessary resources to conduct maintenance activities intended by the designer, life is extended and reliability increased

Preventive maintenance defined as actions performed on a time or run-based schedule that detect 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

Expending the necessary resources to conduct maintenance activities intended by the designer, life is extended and reliability increased

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Dollars are saved over that of a program just using reactive maintenance

Studies indicate that this savings can amount to as much as 12% to 18% on the average

Preventive maintenance will run facility more efficiently resulting in dollar savings

While we will not prevent catastrophic failures, we will decrease the number of failures

Dollars are saved over that of a program just using reactive maintenance

Studies indicate that this savings can amount to as much as 12% to 18% on the average

Preventive maintenance will run facility more efficiently resulting in dollar savings

While we will not prevent catastrophic failures, we will decrease the number of failures



Advantages Cost effective in many capital-intensive processes

Adjustment of maintenance periodicity

Increased component life cycle

Reduced equipment or process failure

Disadvantages Catastrophic failures still likely to occur

Includes performance of unneeded maintenance

Potential for incidental damage to components in conducting unneeded maintenance

Advantages Cost effective in many capital-intensive processes

Adjustment of maintenance periodicity

Increased component life cycle

Reduced equipment or process failure

Disadvantages Catastrophic failures still likely to occur

Includes performance of unneeded maintenance

Potential for incidental damage to components in conducting unneeded maintenance

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Predictive maintenance is a management technique that uses regular evaluation of the actual operating conditions of equipment, production systems to optimize total operation

Condition-based or reliability

Predictive maintenance is a management technique that uses regular evaluation of the actual operating conditions of equipment, production systems to optimize total operation

Condition-based or reliability

Maintenance Strategies (Predictive)Maintenance Strategies (Predictive)



Predictive maintenance defined as 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

Predictive maintenance defined as 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

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Basically, predictive maintenance differs from preventive maintenance by basing maintenance need on the actual condition rather than on some preset schedule

Preventive maintenance is time-based

Activities such as changing lubricant are based on time, no concern is given to the actual condition and performance capability of the oil

It is changed because it is time

Basically, predictive maintenance differs from preventive maintenance by basing maintenance need on the actual condition rather than on some preset schedule

Preventive maintenance is time-based

Activities such as changing lubricant are based on time, no concern is given to the actual condition and performance capability of the oil

It is changed because it is time



Unusual sounds coming out of a rotating equipment predicts a trouble

An excessively hot electric cable predicts a trouble

Simple hand touch can point out many unusual equipment conditions and thus predicts a trouble

Cracks on the Skelton of a buildings or steel rust show problems that need to be fixed

Unusual sounds coming out of a rotating equipment predicts a trouble

An excessively hot electric cable predicts a trouble

Simple hand touch can point out many unusual equipment conditions and thus predicts a trouble

Cracks on the Skelton of a buildings or steel rust show problems that need to be fixed

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Advantages Predictive maintenance is used to define needed

maintenance task based on quantified condition

Eliminate catastrophic failures

Allows for preemptive corrective actions

Decrease in equipment or process downtime.

Decrease in costs for parts and labor

Better product quality

Advantages Predictive maintenance is used to define needed

maintenance task based on quantified condition

Eliminate catastrophic failures

Allows for preemptive corrective actions

Decrease in equipment or process downtime.

Decrease in costs for parts and labor

Better product quality



Disadvantages Increased investment in diagnostic equipment

Increased investment in staff training

Savings potential not readily seen by management

Disadvantages Increased investment in diagnostic equipment

Increased investment in staff training

Savings potential not readily seen by management

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Maintenance Strategy ModelMaintenance Strategy Model

Different dimensions should be looked at when planning maintenance work

Different dimensions should be looked at when planning maintenance work


Maintenance Strategy Model(Decision Diagram)

Maintenance Strategy Model(Decision Diagram)

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Types of Maintenance Types of Maintenance

Other View Other View


Types of Maintenance Types of Maintenance

Maintenance Decision Maintenance Decision

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RepairRepair

Generally, the maintenance scheduling embraces the following activities: Inspection

Repair

Overhauling

Hence the term repair reflect the time duration consumed to perform the corrective action

Based on the time the repair may be minor like adjustment of something or major

Generally, the maintenance scheduling embraces the following activities: Inspection

Repair

Overhauling

Hence the term repair reflect the time duration consumed to perform the corrective action

Based on the time the repair may be minor like adjustment of something or major


Repair and MaintenanceRepair and Maintenance

Repairs Repair activities are reactive

Breakdowns and malfunctions occurs when system in use

Cost is high

Preventive Maintenance Based on regular scheduled inspection

Performed before failure and during ideal time

Repairs Repair activities are reactive

Breakdowns and malfunctions occurs when system in use

Cost is high

Preventive Maintenance Based on regular scheduled inspection

Performed before failure and during ideal time

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At minimum level of preventive maintenance (remedial policies) Do repair only when breaks occur

Cost of breakdowns, interruptions of service and repair is high

As the preventive maintenance efforts increased, breakdown and repair costs decreased

At some point, the total maintenance cost reached its minimum value

At minimum level of preventive maintenance (remedial policies) Do repair only when breaks occur

Cost of breakdowns, interruptions of service and repair is high

As the preventive maintenance efforts increased, breakdown and repair costs decreased

At some point, the total maintenance cost reached its minimum value

Trade-off between Repair and MaintenanceTrade-off between Repair and Maintenance



Annual Cost

Degree of Preventive Maintenance

Minimum TotalMaintenance Cost

PreventiveMaintenance

Cost

Breakdownand Repair

Cost

Total Maintenance

CostsMinimumLevel of

PreventiveMaintenance

Trade-off between Repair and MaintenanceTrade-off between Repair and Maintenance

Low High

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Repair and MaintenanceRepair and MaintenanceHow Speedy Should Repairs Be?How Speedy Should Repairs Be?

Cost

0

MinimumTotal Costof Repairs

Cost of RepairCrews &

Spare Parts

Cost ofInterruptions to

Service

Speed of Making RepairsSlow Fast


Structural Health MonitoringStructural Health Monitoring

SHM is defined as the use of in-situ, non-destructive sensing and analysis of structural characteristics, including the structural response, for detecting changes that may indicate damage or degradation

It is a move from visual inspection to data collection base inspection and monitoring

SHM is defined as the use of in-situ, non-destructive sensing and analysis of structural characteristics, including the structural response, for detecting changes that may indicate damage or degradation

It is a move from visual inspection to data collection base inspection and monitoring

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Structural Health MonitoringStructural Health Monitoring Basic components of SHM Basic components of SHM


Structural Health MonitoringStructural Health Monitoring

SHM aims to provide quantitative data on the real conditions of a structure and detect the appearance of degradations

By installing a number of sensors, continuously measuring parameters relevant to the structural conditions and other environmental parameters

SHM can be used for load estimation (e.g. traffic, wind) and validate design assumptions regarding the static and dynamic behavior of structures

SHM aims to provide quantitative data on the real conditions of a structure and detect the appearance of degradations

By installing a number of sensors, continuously measuring parameters relevant to the structural conditions and other environmental parameters

SHM can be used for load estimation (e.g. traffic, wind) and validate design assumptions regarding the static and dynamic behavior of structures

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Design for Life-CycleDesign for Life-Cycle

The promotion of a design that decreases a facility cost over its life-cycle

The ASCE is currently preparing guidelines for promoting design for life-cycle

The life cycle cost (LCC) of an asset is defined as the present value of the total cost of that asset over its operating life, including initial, occupation, operating costs, and the cost or benefit deriving from disposal of the asset at the end of its life

The promotion of a design that decreases a facility cost over its life-cycle

The ASCE is currently preparing guidelines for promoting design for life-cycle

The life cycle cost (LCC) of an asset is defined as the present value of the total cost of that asset over its operating life, including initial, occupation, operating costs, and the cost or benefit deriving from disposal of the asset at the end of its life


Design for Life-CycleDesign for Life-Cycle

The broad objectives of a life cycle costing may be: To enable more effective investment decisions, taking

into account all costs that may arise from it

To consider the impact of all costs, rather than just capital costs

Too provide information that can contribute to the more effective management of the completed facility

To assist in the evaluation of alternative solutions to specific design problems

The broad objectives of a life cycle costing may be: To enable more effective investment decisions, taking

into account all costs that may arise from it

To consider the impact of all costs, rather than just capital costs

Too provide information that can contribute to the more effective management of the completed facility

To assist in the evaluation of alternative solutions to specific design problems

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Design for DeconstructionDesign for Deconstruction

The usage and end of life impact of construction activities on the ecosystem are to be accessible at the design stage

Design activities must be beneficial to the ecosystem during building usage and end-of-life

The focus of AEC practitioners has shifted from the traditional methods of end-of-life building disposal to modern methods such as deconstruction

The usage and end of life impact of construction activities on the ecosystem are to be accessible at the design stage

Design activities must be beneficial to the ecosystem during building usage and end-of-life

The focus of AEC practitioners has shifted from the traditional methods of end-of-life building disposal to modern methods such as deconstruction



DfD could serve multiple purposes, material recovery for building relocation, component reuse, material recycling and remanufacture

DfD are more concerned with building relocation and component reuse rather than recycling or manufacturing

More challenge is to design buildings that can be deconstructed and its components reused with minimal reprocessing

DfD could serve multiple purposes, material recovery for building relocation, component reuse, material recycling and remanufacture

DfD are more concerned with building relocation and component reuse rather than recycling or manufacturing

More challenge is to design buildings that can be deconstructed and its components reused with minimal reprocessing

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DfD Factors DfD Factors

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