IMPLEMENT MAINTENANCE STRATEGY

AND RELIABILITY METRICS

TO MITIGATE RISK AND IMPROVE EQUIPMENT
PERFORMANCE & SAFETY OF PERSONNEL IN THE INDUSTRIES
Relation between Maintenance and Reliability:
Maintenance Reliability

The combined technical and

The likelihood that an asset
administrative efforts aimed
at keeping an item Operation or item will operate
operational or restoring it to a of the Asset successfully for a designated
condition where it can fulfill time frame under specified
its intended function. conditions.

Why are
maintenance
strategies so
important? 1. A well-planned maintenance
strategy is essential for operating
any profitable business effectively.
2. Without a well-defined
maintenance strategy, the risk of
non-compliance with regulatory
agencies increases, along with the
potential for significantly higher
labor costs.
3. There is an increased safety risk,
with the potential for incidents and
accidents.

pg. 1
 Reduces The Likelihood
Of Asset Breakdowns Improve Health And
And Unexpected Safety
Downtime.
BENEFITS OF
MANINTEANCE
STRATEGIES

Minimizes Expensive Extends Life Span Of An

Repairs And Asset
Replacements Of Parts

TYPES OF MAINTENANCE STRATEGIES

It is very important to choose the best maintenance strategy for a particular
asset or piece of equipment. Maintenance strategies can be divided into 6 top-
notch categories, each ideal for different circumstances.

Preventative Maintenance Strategy Predictive Maintenance Strategy

This proactive maintenance strategy involves This strategy employs data and analysis to
making adjustments, performing cleaning, anticipate equipment failures by leveraging
conducting repairs, and replacing parts to predefined failure modes. It utilizes predictive
ensure the reliability of equipment before maintenance technologies (or CMMS software)
failures and downtime happen. By addressing and IoT sensors for real-time monitoring and
potential issues in advance, this approach insights into asset performance. It allows
helps minimize the need for costly corrective maintenance teams to fix any defects before
maintenance, which is especially crucial for the equipment fails.
safety-critical assets and those vital for
production.

pg. 2
 Reliability-centered Maintenance Risk-Based Maintenance
Strategy
RbM is a maintenance strategy that prioritizes
RCM is a maintenance strategy focused on ensuring maintenance activities based on the risk associated
that systems continue to do what their users with equipment failure. Instead of performing
require in their current operating context. It maintenance based on a fixed schedule or usage
involves; intervals, RbM focuses on assessing the potential
impact of equipment failure on safety, operations,
Identifying Functions Analyzing and costs. Key components of RbM include;
and Potential Failures Consequences
Risk Assessment Prioritization
Determining Implementing and
Maintenance Tasks Reviewing Decision-Making Continuous
Improvement

Run-To-Failure Maintenance Strategy Scheduled Maintenance

Run-to-failure maintenance is a strategy where Scheduled maintenance involves performing routine

equipment is allowed to operate until it fails, at which inspections, calendar-based repairs, and servicing
point repairs or replacements are made. This of equipment at predetermined intervals. This type
approach does not involve routine inspections or of maintenance is planned based on a set schedule,
preventative maintenance. It's often used for non- which can be determined by time periods (e.g., every
critical assets where the cost of downtime is six months) or usage metrics (e.g., after a certain
acceptable or where the cost of maintenance is number of operating hours). The goal is to prevent
higher than the cost of failure. equipment breakdowns and ensure that machinery
operates efficiently and reliably.

pg. 3
 Key Elements To Consider While Implementing
Maintenance Strategy

Determine Essential Assets And Evaluate

The Existing Maintenance Capabilities

Evaluate The Effectiveness Of Your

Current Operations And Establish
Maintenance Goals

Choose The Most Suitable Maintenance

Strategy For Your Assets

Develop A Clear Maintenance Plan

Implement The Maintenance Strategy

Track The Outcomes And Refine Your

Approach

Develop a feedback loop

pg. 4
 What Are Reliability Metrics?

pg. 5
 Types Of Reliability Metrics

Mean Time Average Time Between The (𝐓𝐨𝐭𝐚𝐥 𝐎𝐩𝐞𝐫𝐚𝐭𝐢𝐧𝐠 𝐓𝐢𝐦𝐞)

Occurrence Of One Failure
MTBF =
Between Failures (𝐍𝐮𝐦𝐛𝐞𝐫 𝐨𝐟 𝐅𝐚𝐢𝐥𝐮𝐫𝐞𝐬)
And The Next In A System
(MTBF) Or Component

Measure The Average Time (Total Repair Time)

Mean Time to Required To Repair A Failed
MTTR =
(Number of Repairs)
Repair (MTTR) Component Or System

Average Time A Non-

Mean Time to MTTF =
(Total Operating Time)
Repairable System Or (Number of Failures)
Failure (MTTF) Component Operates Before
It Fails

The Frequency With Which 1 1

Failure Rate (λ) An Engineered System Or λ= Or λ =
Component Fails Within A 𝑀𝑇𝐵𝐹 𝑀𝑇𝑇𝐹
Specific Period Of Time

Proportion Of Time A
System Or Component Is In Availability = 𝑼𝒑𝒕𝒊𝒎𝒆 ×100
A Functioning Condition, 𝑼𝒑𝒕𝒊𝒎𝒆+𝑫𝒐𝒘𝒏𝒕𝒊𝒎𝒆

Availability Relative To The Total Time

It Could Possibly Be In Availability = 𝑴𝑻𝑩𝑭 ×100
𝑴𝑻𝑩𝑭+𝑴𝑻𝑻𝑹
Operation.

Probability That A System R(t)=P(T>t)

Or Component Will Perform ❖ R(t) is the reliability at time t.
P(T>t) is the probability that the time to failure T
Reliability
❖
Its Intended Function
is greater than t.
Function (R(t)) Without Failure For A
R(t)=𝑒−𝜆𝑡
Specific Period Of Time (t) ❖ 𝜆 is the constant failure rate.
❖ t is the time of operation.

pg. 6
 Enhanced Decision-Making Implement Safety
and Resource Allocation Protocols and Standards
1. Risk-Based Maintenance
1. Compliance with Safety
(RBM)
Standards
2. Root Cause Analysis (RCA)
2. Safety Inspections
3. FMEA
3. Lockout/Tagout
Procedures

How Maintenance Strategy

And Reliability Metrics Help
To Mitigate Risk And
Enhance Data Collection
Improve Productivity & and Optimize
Safety? Maintenance Scheduling

1. Condition Monitoring
Systems
2. Data Analytics
Invest in Training and
3. Maintenance Planning
Competency
and Scheduling
Development

1. Technical Training
2. Safety Awareness
3. Emergency
Preparedness Implement Redundancies and
Contingency Plans

1. Spare Parts Management

2. Redundant Systems
Regularly Review and Update Risk 3. Contingency Planning
Mitigation Strategies

1. Continuous Improvement
2. Audits and Inspections

pg. 7
 Foster a Safety Culture and Technology Integration

1. Leadership Commitment 4. Communication

2. Employee Involvement 5. Computerized Maintenance Management System (CMMS)
3. Feedback Loops 6. Automation and Robotics

pg. 8
 How To Implement It
Implementing a maintenance strategy and reliability metrics in an
industry demands a structured approach that aligns with the
organization's operational objectives, safety standards, and available
resources. Here is an example of implementing these strategies
effectively;

1. Assess Current Maintenance Practices 6. Train and Engage Maintenance Personnel

a. Assess Current Maintenance a. Engage Employees
Practices
b. Safety Training
b. Analyze Equipment Performance
2. Define Maintenance Goals and Objectives
c.Technical Training
7. Implement a Computerized Maintenance
a. Align with Business Objectives
Management System (CMMS)
b. Set Specific, Measurable Goals
a. Automate Workflows
3. Choose the Appropriate Maintenance
Strategy
b. Data Integration

a. Preventive Maintenance (PM) c.Centralized Maintenance

Management
b. Predictive Maintenance (PdM)
8. Implement Condition Monitoring Systems
c. Reliability-Centered Maintenance a. Data Collection and Analysis
(RCM)
b. Set Alerts and Thresholds
d. Risk-Based Maintenance (RBM)
c.Install Sensors and Monitoring
e. Other Maintenance Strategy
Equipment
4. Select and Implement Reliability Metrics 9. Monitor, Measure, and Adjust
a. Overall Equipment Effectiveness a. Continuous Improvement
(OEE)
b. Benchmarking
b. Mean Time Between Failures (MTBF)
c. Regular Performance Reviews
c. Mean Time to Repair (MTTR)
d. Feedback Loops
d. Failure Rate 10. Foster a Culture of Reliability
e. Other Metrics e. Employee Involvement
5. Develop a Maintenance Plan and Schedule f. Communication and Transparency
a. Create a Maintenance Calendar g. Leadership Support

b. Resource Allocation
c. Integrate with Production Schedule

pg. 9