This is because primarily RCM is a tool that is designed for use in the design stage of the facility life cycle. Predictive maintenance is more effective at detecting potential breakdowns than preventive maintenance and is more incisive to which actions are actually needed. The bottom line is, if a preventive maintenance program is used, it should go hand in hand with PM optimization. Get your blueprint for building the maintenance team of tomorrow, today. The computer software utilizes data from the sensors and information recorded in the system. In both cases, you don’t know when maintenance is going to happen until a machine breaks down. This workflow is developed to optimize and improve an existing facility maintenance program. This is a strategic maintenance decision intended to prolong facility equipment and systems life and therefore maintain longer periods of production. Price, in Coal Power Plant Materials and Life Assessment, 2014. It is not unlikely, however, that some form of condition monitoring might facilitate running the Ball Mills for longer periods before the lifters and liners need replacing. Infraspeak ©2015-2019 - Brought to you by Facility Management Geeks. Each level of service represents a particular activity or area against which service is measured. is next on the list and can easily be used in conjunction with preventive maintenance. maintenance cost influences unit replacement decisions and vice versa). Additionally, a reliance on data and sensor information means maintenance is determined by the actual condition of equipment, rather than a best-guess schedule or gut feel. Failure-based maintenance is usually considered acceptable for components with low risk of failure. For the refinery, the major work can be smoothed over the year and carried out by an internal labor force; for the power station, extensive use of contract labor – for resourcing the shutdown peak – will be necessary. If the workload varied erratically across such a large plant, the organization would need to be designed to match, i.e. The replacement of large high-cost units of plant is influenced by many factors to include the availability of capital, taxation policy, production needs, maintenance costs and the availability record of the existing unit. Examples of preventive maintenance actions include, Even taking into account the potential waste of preventive maintenance, these costs tend to be much lower than when repairing an asset only when there is already a functional failure. FMEA can also form part of a reliability program such as an RCM study. resources would have to be plant- flexible or greater use would have to be made of contract labor. The maintenance strategy should also ensure the current data in the CMMS is value adding and therefore carry out a “cleansing” exercise. Much of the equipment requires cost in excess of $50,000. Making use of this strategy, the company can avoid downtimes due to equipment machines. it should be easy to find condition-monitoring techniques that would be effective in ‘predicting the onset of failure’. Routine maintenance is any task done on a planned and ongoing basis to identify and prevent problems. Typically asset management plans have the following sections: an executive summary, a description of the asset and key facts, the audience for the plan, the levels of service required and how they are/are not being met, future demand, performance and condition report, historical cost report, summary of current management plans, risk assessment and identification, options development and action plan. Above all, your job as the head of facilities is to create a comprehensive maintenance strategy that is efficient, cost effective, and safe. This step enables the RCM team to prioritize and choose an appropriate maintenance strategy that can tackle the failure. If you are combining this maintenance management strategy with others, it’s a good idea to use a CMMS so you can track the number of times an asset has been repaired or replaced and all of the costs that go along with it. The physical assets of a transmission/distribution system are spread over wide geographic area. In short, reactive maintenance often means more downtime and higher maintenance costs when it’s not used strategically. It provides a structured and systematic framework which can result in an effective maintenance management program for facility equipment. Strategies focused on preventive maintenance. Time-based preventive maintenance is when tasks are scheduled on an asset at a certain time interval, such as the first of every month or every seven days. A simple example would be a lamp, which can be used until it melts and s, We should not, however, mistake reactive maintenance with emergency maintenance, which occurs at different stages of a breakdown. Scheduled offline maintenance or failure of one of the Ball Mills (or its ancillary equipment) causes a 50% loss of milling production. The ultimate goal of RCM is to increase equipment availability or reliability. CBM uses real-time performance data to point out a problem after a machine begins to fail. While it requires minimal planning, the drawbacks of reactive maintenance can be substantial if it’s not carried out correctly. A base-load power station shutdown might well take 12 weeks and employ as many as a thousand artisans. It takes into account the ripple effect of a breakdown in the component. For instance, a manufacturing plant that has a team dedicated to maintenance technology and is owned by a billion dollar company will use predictive maintenance. The technicians come up with a customized maintenance plan for the different machines and equipment. A maintenance strategy involves the identification, resourcing and execution of many thousands of repair, replace and inspect decisions. Most of the maintenance results from time-dependent failure mechanisms (e.g. Visit our Advertise page. Maintenance performance is reviewed periodically and, depending on the results, may be reviewed and updated more frequently. Plant operation is sustained via the alternative crushing process. Here’s a handy way of remembering how to classify the types of maintenance strategies: And here’s how much of each maintenance strategy is planned and how far in advance you can schedule them. RCM is defined by a technical standard from the Society of Automotive and Aerospace Engineers (SAE), namely SAE JA1011 (1999) [5.4]. If the maintenance performance is in line with business objectives, then the facility operation will continue; however, if there is any deviation in performance or change in the facility process or criticality ranking, then the maintenance strategy should be revisited. All Rights Reserved, A look at the tools that empower your maintenance team, Manage maintenance from anywhere, at any time, Track, control, and optimize asset performance, Simplify the way you create, complete, and record work, Connect your CMMS and share data across any system, Collect, analyze, and act on maintenance data, Make sure you have the right parts at the right time, AI for maintenance. In long life assets such as power plants, finding information on operating and maintenance practices, failure events, major rebuilds and costs over a >20-year period is a daunting and costly exercise. and is more incisive to which actions are actually needed. Want to learn more? For example, a sensor may use vibration analysis to alert the maintenance team that a piece of equipment is at risk of failing, at which point it will be taken offline, inspected, and repaired accordingly. The advantage of PdM (over PM) is the potential for cost savings from reduced man-hours spent on maintenance, and more insight as to the performance and potential issues arising with the machine. distribution can then be modeled in more detail – but in the context of the complete system (see Figure 1 in Case study 9 of Chapter 12). We use cookies to ensure that we give you the best experience on our website. We will look at facility integrity KPIs and dashboards in Chapter 9. preparation of spares, job methods, decision guidelines). Finally the maintenance program is updated along with the CMMS. Regular tests and inspection can predict the chances of equipment or its components malfunctioning. A profit-centered maintenance strategy requires effective and reliable maintenance planning, estimating, and scheduling (RMPES) and many other best practices. But predictive maintenance goes a little further by trying to detect faults at an even earlier stage. Using the reliability predication available at discrete points nTs provided by X¯n, the following equation is used to estimate f(TM): where TM∈ℕ, and RTM represents the reliability prediction at TMTs. FMEA may also be referred to in standard SAE J1739 (Potential Failure Mode and Effects Analysis in Design) [5.6] and standard IEC 60812 (International Standard on Fault Mode and Effects Analysis) [5.7]. What are the production targets, i.e. When a piece of equipment malfunctions, it must be repaired (or replaced!). They concentrate on developing an economically optimised long-term maintenance plan, including a schedule of preventive maintenance/replacement activities and a forecast of annual costs to implement the plan. Read our article about it! Currently, businesses are utilizing artificial intelligence in maintenance systems. Instead of waiting for the malfunction to occur, this type of maintenance aims to prevent it from happening. Since repairs are not planned, it’s a good method to employ for equipment that is not essential for operations or has a low cost (think anything that’s rarely used or duplicates the function of other equipment). at any one time only three of the available five thickeners are required). They must be developed by all of the key facility stakeholders and be clear, concise and realistic. As with all maintenance types, there are potential drawbacks to relying solely on preventive maintenance. How hard are you willing to work to save $100? When a piece of equipment malfunctions, it must be repaired (, The same applies to equipment of lower value, as the work required to maintain or constantly monitor it can prove more expensive than repairing or replacing it when it breaks down. It is important to maintain the key principles of RCM and not to overstretch the battery limits that were agreed on by the facility maintenance team at the start of the process. PMO, on the other hand, is specifically designed to target existing maintenance programs. Currently, businesses are utilizing artificial intelligence in maintenance systems.