We don’t need to agree on every little detail of what each strategy means, but we do need to be starting from the same spot. 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]. 1: The initial state of the system is assumed to be fault-free, ζ0=η0=0; for every period TM, if the system is up, it goes to the maintenance state which brings the system to the initial state; and if the system is under repair at TM, we continue the repair, after which the system restarts from the initial state. The maintenance managers advice should be sought but in general he does not take the replacement decision. This in turn governs the shape of the workload. In fact, the higher the risk associated with a particular malfunction, the greater the need for preventive maintenance to increase the asset’s lifetime and reduce unplanned downtime. A base-load power station shutdown might well take 12 weeks and employ as many as a thousand artisans. If used correctly, your team can receive reminders and notifications of upcoming repairs and inspections. : This is a technique that uses condition-monitoring tools to track the performance of equipment during normal operation to detect possible defects and fix them before the asset fails. This, however, is a long-term approach and the most cost-effective attack is likely to be the adoption of a condition-based policy. The maintenance workload might have a peak/trough ratio (shutdown/normal) of up to 10:1, which would necessitate the employment of contract labor. Computerised Maintenance Management Systems (CMMS) like Infraspeak exist to help you define, execute and monitor your maintenance strategy. The required level of serviceability of the structure can also dictate the extent of repairs. Clearly there is a balance to be had with cost of ownership versus additional value added, particularly with this strategy. This allows for risks to be managed on an on-going basis. It is a process of determining the approximate time that a machine or its component will fail. This process involves reviewing the selected maintenance tasks and grouping them in a logical way so that they can be uploaded into the facility CMMS. We have discussed the concept of criticality in Chapter 4. This is achieved by setting key performance indicators (KPIs) to assess the facility maintenance performance. Mitigation plans are then prepared for each and every defect identified in order to eliminate the failure mode. 8.3. With the development of an effective asset management system, much of the data to support the assessment will be more readily available and the reviews can be made as a more routine part of doing business. Every asset, technician, and business is unique, and what works for one maintenance team may not work for another. What are you spending, all-up, on maintenance in general and for each asset? The following simplified example is offered as an illustration. A poor understanding of the machinery and asset management can lead to break downs in the assets and downtimes in the business operations. The stationary availability A2(TM) of the overall system with maintenance period TM is then given as follows: Taking derivative with respect to TM, we have, Usually the cost of repair is much higher than scheduled maintenance cost due to the interception of regular operations, so SMSR<1. You can also use a CMMS to track the inventory of spare parts needed to support your run-to-failure maintenance strategy. The main job is the repair or replacement of the lifters and liners, but other work is carried out on the mill to ensure its reliable operation over the following 4 months. Is it downtime, parts, labour, or something else? Higher upfront cost than more basic maintenance strategies. Need a quick comparison of these four strategies? In fact, eMaintenance provides companies with predictive intelligence tools (such as a watchdog agent) to monitor their assets (equipment, products, process, etc.) On the other hand, PdM takes all information into account (past, present, and future) and offers an ideal time for maintenance before any failure, however small, occurs. Generally, the maintenance strategy is classified into two categories, based on the repair timing: corrective maintenance and preventative maintenance (DoD, 2008), as shown in Fig. RCM is defined by a technical standard from the Society of Automotive and Aerospace Engineers (SAE), namely SAE JA1011 (1999) [5.4]. Reactive maintenance has none of that foresight, making it unplanned. The information in these asset management plans also informs decisions that influence plant life estimation and extension. For example, small cracks in concrete structures are tolerable in most cases and yet for water-retaining structures and those exposed to chlorides and aerosols they are not tolerable. A fixed-time replacement model for a unit of plant when new, the units-operating cost is 0 (£year).Thus, rises linearly with time at a rate I (£/year/year) so that after n years the operating cost would be 0 + ni (£/year) and averaged over that time the mean-annual-operating cost would be 0 + (ni/2) (£/year). 10.7. It is usually driven by budget and resource constraints. Do you consider that there is a better way of maintaining the crusher circuit? Reactive maintenance is the mad scramble to fix a machine after it breaks down. The next step in the process is to identify and evaluate the effects of the equipment failure. Read our article about it! Failure-based maintenance is usually considered acceptable for components with low risk of failure. This type of maintenance management strategy is mostly used in larger organizations with more complex operations. What would be the difficulty in using a fixed-time maintenance approach for the crusher circuit? Another thing to keep in mind with predictive maintenance is that you have to walk before you can run. Formulating a maintenance schedule for the plant (see Figure 4.11).
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