Chapter (2) 2.0 Maintenance Management System: November 2017
Chapter (2) 2.0 Maintenance Management System: November 2017
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2.1 Maintenance:
2.2 History:
Until the 1920s, the emphasis was upon those physical assets that
limit or contribute to interrupted production. The function was mainly in
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the hands craftsmen or engineers. They sought technical solutions to the
problems of more reliable power transmission, better ways to lubricate
shafts and bearings, materials that would prevent sever corrosion, etc.
Management of the maintenance function was haphazard and neglected.
In general, maintenance ineffective and costly. [2]
Maintenance' found itself ' during the World War II, when the goal
for industry was production at any cost. With this goal came the
realization that good maintenance was the key to high production, and
required the same kind of effective management as did good production.
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4- Increased cost of production equipment, which intensifies
pressure for greater equipment utilization.
5- Increased ratio of maintenance employees to production
employees, which means fewer men on the do side of plant
operations and more men on the keep ready side.[2]
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i. To maximize the availability and reliability of all assets,
especially plant, equipment and machinery, and obtain the
maximum possible return on investment.
ii. To extend the useful life of assets by minimizing wear, tear and
deterioration;
iii. To ensure operational readiness of all equipment at all times
required for emergency use, such as stand by units, fire
fighting and rescue units, etc.; and
iv. To ensure the safety of personnel using the facilities.[3]
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proactive form of maintenance. Timing plays a major role in all these
approaches [5]. Various forms of maintenance and the relationships
among them are shown in figure (2.1).
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of reducing emergency maintenance and the associated costs in machine
stoppages.' This can be classified into two main activities - preventive
and corrective. [2]
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parameters. [2]
Maintenance which can only be carried out when the plant or unit
is not in use. This is also called off line maintenance. [2]
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Figure (2.2): A decision tree illustrates the relationship among various forms of
maintenance [3]
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2.6 Maintenance Planning and Control
Total maintenance planning embraces all activities necessary to
plan, control and record all work done in connection with keeping an
installation to the acceptable standard, by using the appropriate
maintenance system. In a fully controlled situation, only the time spent on
emergency work is 'unplanned' and this could also be altered by changing
from emergency maintenance methods to a policy of planned
maintenance.[10]
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Figure (2.3): Relation between plant structure and maintenance decision-
making [3]
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2.7 Maintenance Policies:
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And provide a structure which will combine them in a
comprehensive system of management. Figure (2.5) shows a number of
maintenance policies that can be specified, individually or in
combination, for each unit of plant. The rationalized sum of such
specified policies for the whole manufacturing plant constitutes the
maintenance plan.
The action carried out before the failure of equipment / plant can
be regarded as preventive and those carried out after the failure as
corrective. Preventive maintenance actions are deterministic and carried
out separately according to a preventive maintenance program. Because
of the probabilistic nature of failure, and the uncertainty surrounding
corrective maintenance decision making, corrective maintenance cannot
be programmed. However, it is essential to formulate corrective
maintenance guidelines for critical units of plant for effective decision
making after failure.[3]. In what follows, major maintenance policies are
explained in some detail.
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alternative policies for such items could be 'conditioned based
maintenance. [3]
There are two major reasons for not applying CBM in certain
circumstances. First, is not possible to detect all causes of plant failure in
advance. Second, it involves high man power and monitoring cost, and
furthermore it is difficult to monitor some parameters. [5]
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by condition based criteria. The primary aim is to restore the unit to an
acceptable condition economically. [3].
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2.8.1 Classification and Identification of Equipment:
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Management Information system (CMMS), are productivity enhancing
software programs used by industry to better manage capital assets. [8]
1. Asset Management
2. Work Order Management
3. Preventive Maintenance Planning
4. Inventory Management
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Figure (2.5) :Flow-chart of CMMS functions.[13]
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2.11 Implementing CMMS:
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analysis before investing in additional or new CMMS capabilities. The
manager should only acquire what is necessary to accomplish the
maintenance organization's goals. [8]
2.12.2 Equipment
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information, such as building equipment downtime failure code
hierarchies for use in maintenance management metrics. [8/12]
2.12.3 Resources
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Define lock-out/tag-out procedures.
Define tag identifications for specific equipment and locations.
Define safety plans for multiple equipment or locations.
View and linking documents.
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2.12.6 Work Request
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Planningin planning, labor assignments would be planned for
future shifts. Each person's calendar availability would be considered
when the assignments are made. The assignments would be created
sequentially over the shift, filling each person's daily schedule with
priority work for the craft. It could even split larger jobs over multiple
shiftsautomatically.
The CMMS could provide a rapid and easy means for opening,
reporting on, and closing work orders, and reporting work on small jobs
after-the-fact. Labor, materials, failure codes, completion date, and
downtime could all be reported.[8]
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Generate time-based PM work orders based upon last generation or
last completion date. Next due date and job plans should be
displayed.
Permit and track PM extensions with adjustments to next due date.
Trigger meter-based PM by two separate meters.
Print sequence job plans when wanted.
Create a PM against an item so new parts have PM automatically
generated on purchase.
Specify the number of days ahead to generate work orders from
PM Masters that may not yet have met their frequency criteria.
Consolidate weekly, monthly, and quarterly job plans on a single
master.
Assign sequence numbers to job plans to tell the system which job
plan to use when a PM work order is generated from a PM Master.
Permit overriding frequency criteria in order to generate PM work
orders whenever plant conditions require.
Route PM with multiple equipment or locations.
Generate work orders in batch or individually for only the
equipment wanted.
2.12.11 Utilities
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2.12.12 Facility/Equipment History
2.12.13 Purchasing
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provides a picture of each contractor's past performance, current loading,
and planned work. It could include information on specifications,
Government furnished property, quality assurance, payment processing,
delivery orders issued, schedules, and related matters. It could cover both
contracts for facilities maintenance and support services.[8]
The CMMS can be utilized to accumulate the data for KPIs for use
in evaluating the organization's maintenance program. The maintenance
management organization must select the metrics to utilize in establishing
their goals and to measure progress in meeting those goals. The
importance of selecting the Right Key Performance Indicators cannot be
overstated. The KPIs must be based on data that can be obtained and
provide meaningful information that will be utilized in managing the
organization.[8]
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