By determining the work details up front before the actual work takes place, planning allows for the most efficient use of maintenance resources. Outage planning: someone in this new department has to do this. So we need to order it to supplier and wait for part arrival. Time-Based Maintenance refers to replacing or renewing an item to restore its reliability at a fixed time, interval or usage regardless of its condition. Across industry, many definitions are used when it comes to the different types of maintenance. He essentially was saying that plans often don't work out the way you lay them out once an actual emergency arises; however, the planning process makes you thoroughly explore all poss… whereas preventive maintenance is maintenance that has been identified to … Thanks for your comment Alex. Thanks for clarifying the types of maintenance tasks. Examples of Risk-Based Maintenance would be Risk-Based Inspection as applied to static equipment like vessels and piping or even pressure relief valves. If evidence can be found that something is in the early stages of failure, it may be possible to take action to prevent it from failing completely and/or to avoid the consequences of failure. BOX 81310 – 80100, Mombasa, Kenya Abstract:- The general objective of this study was to identify factors that influence effective strategic planning It is more expensive, less efficient, and less safe. This is why the “time-based” maintenance is weak. So Emergency Maintenance is the one and only maintenance type that we really want to avoid as much as possible. The cause will vary from wrong operational, equipment failure, and many more. prepared beforehand and therefore are typically very urgent, inefficient and a costly way to do maintenance. Just a cent from me. It is really good reading. Thanks for the comment, indeed many corrosion mechanisms are time / duty related and can be effectively managed with a time based preventive maintenance regime. For your research, how about looking into how aviation maintenance & reliability practices can be brought in to industries like Oil & Gas? The operator must have depth understanding as well on the concept of deferred maintenance approach since its original/initial “positive” objective (e.g. Staff engagement generates additional input and helps build their commitment to the end plan. long term high cost, equipment efficiency degradation, costly emergency intervention, major accident event, etc.). Planning is one of the main processes of effective maintenance departments. When relationships between Maintenance Planners, Operations, the Maintenance department and Management run smoothly, there are great benefits for all involved. We have certain schedule for each equipment. Can I know what is the suitable type and strategies of maintenance for heritage building? Hi Erik, You never cease to provide a wealth of knowledge. Will I need a maintenance planner/ scheduler clerk(s)? I had faced many times discussions with Maintenance heads on which is their maintenance strategy, and it is very frustrating that we have to start from basics and jump into a maintenance strategy or philosophy to respond to the business or equipment requirements. The secret to effective project planning and management is staying organized and communicating well with your team and stakeholders. Thanks. I would say that the most important thing is that you apply the right type of maintenance to the failure mode you are trying to manage. 1. Hi Jacob, thank you for your comment. A common rule of thumb is that the interval between CBM tasks should be one-half or one-third of the P-F interval. Scheduled restoration tasks and replacement tasks are examples of preventive maintenance tasks.” 1Ramesh Gulati, Jerry Kahn and Robert Baldwin. All take data from equipment and equipment not stop, it call Predictive Maintenance/Condition Based Maintenance.And then using data, make trending. Sometimes it seems to me that we are banging our heads against the wall … Planning is the synthesis of various forecasts—short-term or long-term, special or otherwise. So although a run-to-failure strategy can be a good option, make sure you decide wisely. Some people thrive in this type of environment and often get heralded as heroes when they’ve worked 16hrs non-stop to get production back online. It’s so useful information , When the P-F interval is only a few days the resulting organisational and workplace actions are much like a breakdown and the value of CBM is largely lost. Work-related diseases and ill-health are more difficult to measure due to their long latency period but result in Problem with page? Thank you for the interested topic. I do not like talking in terms of PM, CM, PdM etc as it makes the picture blurred. They do not represent a mathematical “partition” of all the maintenance tasks. In this article, we'll look at the steps you can take to do this, thereby making time for the work that really matters, while still leaving time for personal development, family and friends. Wrench time is basically the time your technicians are doing actual maintenance tasks so that excludes travel time, waiting time, time spent looking for parts and materials, time spent waiting for permits, time spent on breaks or meetings etc. the failure modes are hidden. Otherwise there are no garanty to remain preventive. Size of the market depends upon the sales potential rather than on the geographical areas. Doing so i also discovered, even if this is odd, that those concepts are not always properly defined in academic books, and even in some standards. Preventive maintenance covers multiple types of maintenance that are used before a failure has occurred. To me this distinction is key for understanding, and clearly missing in the maintenance litterature. Once you put time and energy into a thing you start to feel responsible for it. A guide for health and safety representatives Health and safety August 2010 Download Maintenance in the workplace guide [PDF]. The interval can be time-based (days, weeks or months) or usage-based (operating hours, cycles or km). Design your MPS processes to do exactly that! If you are testing e.g. What are the steps that I need to take into account to develop a maintenance planning department? Instead, I would suggest you look for reliability, availability or OEE benchmarks in your industry. Whether you decide to use project management software or not, think about where and how you store all the materials and resources that relate to your project—keep everything in one place if you can. Second is about Surveillance / monitoring tasks And since these failures are hidden, you’ll need to find them before you are relying on that equipment to protect you. Why the FMEA is my equipment not reliable? If you're interested to find more about how to best manage failure modes don't forget to check out my article Reliability Centered Maintenance - 9 Principles of Modern Maintenance. So just suggest me we have to follow instruction of maker or we can run our equipment on the basis of our analysis. I have to do better then this. It is what you do when you are lazy in your personal life, or “want to optimize” maintenance in your professional life. Hi ghassan, I wrote this based on my own industry experience, but there are actually a couple of international standards that cover this and where most of the industry terminology comes from. Oil changing work is too expensive. Whether you should replace or repair/overhaul a complex asset would depend on factors like the cost of repair ve cost of replacement and whether you expect to get the same reliability and life out of a repaired asset vs a new asset. When most people talk about preventive maintenance they really mean Time Based Maintenance which is a repair or replacement on a fixed interval irrespective of the condition of the equipment. Would you allocate all the costs to preventive maintenance or would you only allocate the cost for the initial inspection to preventive/proactive maintenance and allocate the repair/bring back to original state to corrective/reactive maintenance? Greetings! So to level the playing field, it is necessary to explain the way in which a few of these terms have been utilized throughout this document to ensure common understanding by all who read it. after so many hours of service a component is overhauled = restored. Online training, coaching and consulting services in all aspects of Maintenance, Reliability and Asset Management. my question is : what kind of maintenance can i implement for long off standing LV motors in oil and gas field to keep the resources But you would probably use deferred corrective maintenance for any lighting maintenance, i.e. Factors That Influence Effective Strategic Planning Process In Organizations Job Kipkemboi Kiptoo, Dr. Fred Mugambi Mwirigi, 1,2Jomo Kenyatta University of Agriculture and Technology. Instead I always like to point out that non-age related failure modes are typically > 70% of the failure modes we need to manage. 9. This an interesting question and generally speaking unplanned corrective maintenance i.e. However, as I’m often asked questions about the different types of maintenance I decided to put a quick overview together of the types of maintenance. I have confused about preventive maintenance and which better: renewal or replacement of complex assets. It will give you good ammunition to have those discussions with managers and leaders stuck with old beliefs. More To get further details on the picture I like to have split for Planned i.e. Probably a better term could be used, i personally prefer the term “surveillance”. Time Based Maintenance assumes that the failure is age related and a clear service life can be determined. Quite a few will be lagging but there are plenty of leading indicators, it all depends on your goals and objectives. Click this link to get free access to 14 hours of Plant Wellness Way videos. It gives me a clear picture whether we are doing PM or PdM more. I found all your articles very helpful. The Table below shows a brief summary of: An efficient and effective Preventive Maintenance Program will have a mix of all these different types of maintenance. Depending on the quantities of oil involved and the potential replacement costs, it might be worth to hire an external specialist to help with this and develop a long term strategy. Hi Moses, there are many KPIs or performance metrics that you can use to manage and improve maintenance. needs. Hi Tom, If during a PM you find a defect that will eventually lead to a failure then I would consider correcting that defect still a PM as you are still preventing the failure from occurring. If you have a failure mode that is random in nature you would want to opt for a condition-based or predictive maintenance task so that you can see the potential failure coming closer and take action before the failure occurs. That means that under normal operating conditions you will not know whether this equipment is still functional i.e. This would help the leader to make decision in selecting and prioritizing between business or safety. Which is the best way to make the necessary work processes? Thanks Engr.Erik, Don’t forget that for a complex asset the overall failure pattern would most likely be random (see my article on the principles of modern maintenance) in which case time-based repair or renewal would not be an effective strategy. But not always. Definition of Manpower Planning: Manpower planning may, be defined as, “the replacement planning which analyse labour turnover, recruitment policy, promotion, development and maintenance of employee programmes and assess … 4 Reactive Corrective Reset (RCR), basically the resetting of the system after Operator Error or a system freeze or lockout. If you try and go it alone you’ll only have your perspective to guide you, and you won’t have any input from the people who will actually be doing the work and … Importance of Planning: Planning is the key to success of an organisation. (n.d.). Many tasks can be performed exactly the same way, but just under different circumstances. Principles. But in my view with the advent of Artificial Intelligence, much lower costs of equipment sensors (IIoT) and machine learning there is clearly a difference appearing between Predictive Maintenance (PDM) and Condition Based Maintenance (CBM), at least in my view. Inspections, vibration rounds, lubrication rounds, … are clearly preventive maintenance, but what if the preventive maintenance (e.g. The Factors Involved in HR Planning in Organisations. This often leads to prolonged work hours. Plus, preventive maintenance would have much less impact on production than breakdown maintenance (i.e. Time Based Maintenance can never effectively manage non-age related failure modes and therefore should only form a small part of your overall maintenance program as >70% of the failure modes in your plant are not age related (refer to the article 9 Principles of Modern Maintenance). Thus taking regular inputs from the I see Predictive Maintenance as an extension, a more advanced approach to CBM where we use potentially many process parameters gained from online sensors to determine if our equipment is moving away from stable operating conditions and is heading towards failure. Takes many glances before a polish is performed, usually ! Thank you for the comment Eyadeh. I prefer to keep the planned and unplanned distinction for (corrective) maintenance to identify those maintenance tasks that have not been planned i.e. Thanks for the detailed description of maintenance. We conclude that when we do PM, we do CILT (Clean Inspect, Lubricate, Tightening). These 6 ‘foundational pillars’ of maintenance planning include having a separate department for planners, focusing on future work, maintaining component level files, estimating based on the planners expertise and relying on historical data, recognizing the skill of the … In the rest of this article, I will discuss each of these different types of maintenance I detail: But before we delve into those definitions, let's have a look at the fundamental difference between preventive maintenance and corrective maintenance. 7 Emergency Corrective Maintenance (ECM) covers any maintenance task from any of the methods of finding is of a mission critical nature or life preserving that just needs to be fixed right now. This book covers the details of what occurs at the low levels of a planning and scheduling process. and wish you success. Hi Alok, Thanks for the question. Where can I get information on best practices? Scope: Use of Reliability Centred Maintenance (RCM) & Failure Modes Effects Criticality Analysis (FMECA) to review the maintenance strategy of a leading WA process plant that had low availability and reliability causing low tonnages and high maintenance costs. I think that putting a focus on breakdown maintenance (what I tend to call emergency maintenance) is really good as it helps to get out of the reactive environment. Thank you heaps Erik. For further insight, feel free to read my article: For failure modes where the P-F interval shows a large variability, condition monitoring is not an effective strategy. Immediately download all the information that you need to know about best practice Maintenance Planning and Scheduling with our PowerPoint presentation from our 3-Day Maintenance Planning and Scheduling for Reliability training course PPT (PowerPoint) presentation available for purchase at the online store. But, in many people’s mind, breakdown maintenance is urgent maintenance, maintenance that needs to be done right now i.e. would please help me in suitable originations chart for oil company maintenance Section Very knowledgeable article. (n.d.). Hi Wirza, that aligns quite well with what I describe. Online Maintenance Planning and Scheduling Training Course. There quite a few ways to measures reliability as a performance metric, but I often recommend the use of uptime as a relatively simple metric that is easy to measure and understand. i want to ask The executive and middle level managers of your company are the ones most in touch with the end customers. Could be a measurement (size, current level, vibration level, reaction speed, aspect, sound, smell, etc) or some functional check leading to a conclusion regarding the equipment condition or level of performance regarding a function. and recent fallen oil price. every 150 cycles, every 10,000hrs or like your car: service every 10,000km. 6 Reactive Corrective Maintenance (RCM) is any damage fault caused by unpredictable causes like a prisoner filling an intercom with toothpaste or lighting strike. Obviously TBM has an important part to play in any maintenance strategy and this is getting pushed out by the penny pinchers. But when it comes to the Road to Reliability it is a dead end. If you came to one of our three day Maintenance Planning and Scheduling Training Courses you would learn all that you need to know about maintenance planning and scheduling process design and the maintenance planning and scheduling process contents. Objectives 4. This is the glance to the shoe leading to the potential decision to polish it. And if that’s the case for you, you know what to do: get rid of it! NOTE: Find out how you can do our certificated online 10 module Maintenance Planning and Scheduling training course by distance education. Hi Ahmed, thanks for your comment. As opposed to intervention where something is “made” to the equipment to restore its function, here nothing is made but the condition regarding a function is checked or assessed. Unfortunately books rarely specify this distinction, which leads to mixing oranges and apples under the same general term of “maintenance tasks”, which not enough precise to correctly describe the other maintenance concepts within preventive maintenance. Mike Sondalini Managing Director Lifetime Reliability Solutions HQ. It is important to realise that in many industries companies do have to complete certain tasks to meet regulatory compliance requirements and these would typically be executed on a fixed time interval i.e. If you've found this article helpful and would like to get your own PDF copy of the article and a supporting presentation that explains the different types of maintenance and when to use them simply click on the link below and leave your details: And frequently asked question is ‘what is breakdown maintenance’ and as it’s not in my explanation I thought I’d just covered it here briefly. Maintenance workload, order replacement parts and schedule maintenance items to success of an.. O & G business situation where cost optimization and minimal production interruption ) could falling... Of warning that they are usually simple, less expensive than interventions risk equipment may be at! Urgent, inefficient and a costly way to improve capacity or reduce and. 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Or reduce maintenance and which better: renewal or replacement of complex assets defects that the interval be. Reactive maintenance culture makes sense to me your current intended output does not go far enough general!, preventive and corrective, its call wrench time legislative requirements fail yet article you will up...