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Technical Series:
Reliability, Maintenance and Asset Management
Whitepaper # I:
Authors:
PhD. Carlos Parra Mrquez
PhD. Adolfo Crespo Mrquez
Dept. Industrial Management. University of Seville
School of Engineering, University of Seville, Spain
Edited by:
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October, 2016
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I.1. INTRODUCTION
It can be demonstrated (Crespo, 2007), that for the effective and efficient
maintenance management, it is possible to achieve the previous points by thoroughly
understanding the following two aspects:
a) The process of maintenance management, which has a course of action, this is to
say a series of steps to follow and;
b) The general framework of reference for the management, i.e. the basic support
structure consisting of a series of tools that make up a basic system, which is
necessary for an advanced maintenance management.
We can divide the maintenance management process into two main parts:
(i) The definition of the strategy of maintenance;
(ii) The implementation of the strategy of maintenance.
The first of these parts, the process of defining the strategy of maintenance, requires
the definition of the objectives of maintenance as its "input". Obviously, the objectives
of maintenance arise directly from the business plan of the Organization in question.
Designing maintenance strategies that are aligned with business plans is a key aspect
and conditions the attainment of the objectives of maintenance and ultimately the ones
described in the business plan of the organization.
The second part of the process, the implementation of the strategy has a different level
of importance and has to do with our ability to ensure adequate levels of training of staff,
preparation of work, the selection of the right tools to perform different tasks or, for
example, the design and achievement of the run time of different maintenance programs.
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The first and second parts in which we divide the maintenance management process
determine the effectiveness and efficiency of management respectively. Efficiency
shows the benefits with which a Department or function achieves the objectives pursued
based on the needs of the company. The effectiveness of the business functions is often
measured in terms of quality of the service provided by this function, always from the
customer-supplier standpoint and the perspective of the client. The effectiveness of
management focuses then on the degree of correctness of the processes undertaken and
on the processes to produce the expected.
The second part into which we have divided the maintenance process has to do with the
efficiency of our management, which should be less important than the first one (to ensure
its effectiveness) for the organization. Efficiency is acting or producing with minimal effort,
minimizing leftover or waste of resources, and the costs associated therewith. If we achieve
improvements in this second part of the management process, this will enable us to
minimize the direct costs of maintenance, i.e. perform a maintenance service of equal or
better quality at more competitive costs (Parra and Crespo, 2015).
The process of defining a strategy for maintenance can be described using well-known standard
methods of strategic planning, which usually include the following (see Figure 1.1):
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Figure 1.1. Model for defining the maintenance strategy (Crespo, 2007)
After having transformed the priorities of the business into priorities of maintenance,
maintenance managers shall make their medium-term strategies to tackle potential weaknesses
in the maintenance of the equipment, in accordance with these objectives. In this way a generic
maintenance plan in the company is obtained which then needs to be developed. The
development of this plan will entail, as a fundamental point, specifying a series
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of policies to be carried out for assets that are deemed critical. At this same level, another
series of actions can be provided on aspects that have to do, for example, with the
requirements for skills and technologies to be used for the improvement of the effectiveness
and efficiency of maintenance at a micro level, but require investment consideration.
Secondly, the actions at the tactical level must determine the correct assignment of
maintenance resources (skills, materials, test equipment and measurement, etc.) for the
concession of the maintenance plan. As a result, a detailed program will be materialized with all
tasks to be developed, with all the appropriate resources to carry it out. In addition, during the
detailed process of planning and scheduling of maintenance needs, this level of activity in the
company must develop skills that will allow it to discriminate between different options of
resources at its disposal (of a different cost), that can be assigned to a specific task in a specific
asset (for example, a particular machine), the place of performing the task and start and run
time. This will detail explicitly the policies of maintenance at the tactical level.
The actions at the operational level should ensure that maintenance tasks are
completed adequately by the technicians selected, at the agreed time, following the
additional procedures and using the appropriate tools. As a result of the above, work
will be performed and the corresponding data will be collected to be introduced in the
management information system. Operational procedures will be necessary for
preventive activities, repairs and diagnosis of complicated failure.
Now what has been previously commented becomes concretized in a simple and
practical manner, always bearing in mind enabling the maintenance managers to carry
out the implementation of the above concepts. A proposal for a generic maintenance
management model (MMM) (Crespo, 2007) is thus presented which takes into account
and integrates many of the models found in the literature to date, or of employees in
practice in companies of long tradition and excellence in this field (Pintelon Gelders,
1999 and Vanneste and Van, 1995).
As indicated in the figure of reference of MMM, the first three blocks determine the
effectiveness of the management, the following blocks assure the same efficiency and
continuous improvement in the following way: blocks 4 and 5 include actions for the planning
and scheduling of maintenance, including, of course, the capacity of planning of department of
maintenance. Blocks 6 and 7 are dedicated to the evaluation and control of the
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maintenance and the cost of assets throughout their life-cycle. Finally block 8 focuses
on actions to ensure continuous improvement of the management.
As was previously mentioned, the support structure includes a set of techniques that are
needed. This structure contains a series of pillars that can be classified as follows
(Crespo and Gupta, 2006):
- The pillar of information technologies (IT pillar). Here we include the GMAO (tools
of computer support to the maintenance management, for example SAP PM,
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In Figure 1.3, we present a practical model which includes the use of some
commercial tools related to the areas of maintenance and reliability engineering, tools
that fit into each one of the 8 blocks (8 stages) of MMM.
Then we will briefly introduce each technique and discuss how it can be of greater help to
the processes of decision-making that take place at each stage of the process. In this way we
may also characterize the support structure of the maintenance management model (MMM):
- Phase 1. Techniques to define the maintenance strategy management. In order to
ensure that operational maintenance objectives and strategy are not inconsistent with
the general objectives of the business (Gelders et al., 1994), we can introduce and
implement techniques into the area of maintenance such as the Balance Scorecard
(Balance Scorecard BSC - (Kaplan and Norton, 1992)). The BSC is specific to the
Organization for which itis developed and allows the creation of a series of key
performance indicators (KPIs) to measure the performance of the maintenance
management, which are aligned with the strategic objectives of the organization.
Unlike other conventional measures that are aimed at control, BSC places in the
center of its analysis the global strategy and the vision of the business thus
emphasizing the achievement of a series of goals in the performance of the
organization. These goals are designed to align people with a general vision for the
organization. The goals for the selected indicators are established following a
participatory process that requires the involvement of agents inside and outside the
organization of maintenance, the participation of the direction of the company, and
the personnel considered key in the operational units of the maintenance function,
along with key users of the service (phase 1). In this way, the measures of
performance of the maintenance function are linked with the success of the
Organization in full. (Tsang et al., 1999).
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obvious, but the life-cycle cost analysis depends crucially on values derived
from reliability. For example, on the analysis of the failure rate, on the cost of
replacement parts, on the time of service, on the costs of components, etc. A life-
cycle cost analysis is important to decide on the acquisition of new equipment
(replacement or new acquisition) (Campbell and Jardine, 2001), which provides
three important benefits:
- All costs associated with an asset become visible.
- It enables an analysis between business functions. For example, to check
how low costs of R & D can lead to high costs of maintenance in the future;
- They allow management to make accurate forecasts.
- Phase 8. Techniques for the continuous improvement of the maintenance. The
continuous improvement of the maintenance management (phase 8) will be possible
using techniques and emerging technologies in areas that are considered of high
impact as a result of studies carried out in earlier phases of our management process.
With regard to the implementation of new technologies of maintenance, the "e-
maintenance" concept emerges as a component of the concept of "e-manufacturing"
(Lee, 2003), which promotes the benefits of new information and communication
technologies to create multi-user corporate and distributed environments. "E-
Maintenance" can be defined (Tsang et al., 1999) as a maintenance support which
includes resources, services and management needed to allow the implementation of
a proactive maintenance decision-making process. This support includes not only
technologies of Internet (i.e. ICT, Web-based, WIFI, wireless, informatics
technologies) but also "e-maintenance" activities (operations and processes) such as
"e-monitoring", "e-diagnosis", "e-prognosis"... etc. In addition to new technologies
for maintenance, the participation of the maintenance people within the
improvement process will be a critical factor for success. They will certainly require
the highest levels of knowledge, experience and education (training), but at the same
time, the simple techniques that will allow the involvement of operators in the
performance of maintenance tasks will be extremely important to achieve the
highest levels of quality of maintenance and the overall efficiency of the equipment.
This first whitepaper of introduction, briefly summarizes the process (course of actions and
the number of stages or steps to follow) and the reference frame (the essential support
structure and the basic system) necessary for the implementation of the maintenance
management model (MMM) proposed in Figure 1.2. A set of practical methods are
presented to improve decision making in maintenance management, which are also
classified according to their most convenient use inside the MMM (Parra and Crespo,
2015). Later, in the following chapters of this book, we will be describing in detail the
various stages of the comprehensive management model of the proposed maintenance. Its
contents are composed of a total of twelve chapters, which are summarized below.
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- Campbell JD, Jardine AKS, 2001. Maintenance excellence. New York: Marcel Dekker.
- Crespo Mrquez A, 2007. The maintenance management framework. Models and
methods for complex systems maintenance. London: Springer Verlag.
- Crespo Mrquez A, Gupta JND, 2006. Contemporary maintenance management:
Process, framework and supporting pillars. Omega, 34(3): 313-326.
- Duffuaa SO, 2000. Mathematical models in maintenance planning and scheduling.
In Maintenance, Modelling and Optimization. Ben-Daya M, Duffuaa SO, Raouf A,
Editors. Boston: Kluwer Academic Publishers.
- EN 13306:2011, 2011. Maintenance Terminology. European Standard. CEN
(European Committee for Standardization), Brussels.
- Gelders L, Mannaerts P, Maes J, 1994. Manufacturing strategy, performance
indicators and improvement programmes. International Journal of production
Research, 32(4):797-805.
- Kaplan RS, Norton DP, 1992. The Balance Scorecard- measures that drive
performance. Harvard Business Review, 70(1): 71-9.
- Lee J, 2003. E-manufacturing: fundamental, tools, and transformation. Robotics and
Computer-Integrated Manufacturing, 19(6): 501-507.
- Moubray J, 1997. Reliability-Centered-Maintenance (2nd ed.). Oxford: Butterworth-
Heinemann.
- Palmer RD, 1999. Maintenance Planning and Scheduling. New York: McGraw-Hill.
- Parra, C., and Crespo, A. 2015. Ingeniera de Mantenimiento y Fiabilidad aplicada
en la Gestin de Activos. Desarrollo y aplicacin prctica de un Modelo de Gestin
del Mantenimiento (MMM)". Segunda Edicin. Editado por INGEMAN, Escuela
Superior de Ingenieros Industriales de la Universidad de Sevilla, Espaa.
- Parra Mrquez Carlos, 2010. Proyecto de implantacin del Sistema de
Administracin de Activos (SAA) de la ACP (Autoridad del Canal de Panam).
Informe tcnico: Editado por IngeCon, Panam, 07-2010-V1.
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Authors:
PhD. MSc. Eng. Carlos Parra Mrquez (Venezuela)
PhD. MSc. Eng. Adolfo Crespo Mrquez (Espaa)
E-mails: parrac@ingecon.net.in, adolfo@etsi.us.es
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Escuela Superior de Ingenieros de la Universidad de Sevilla, Espaa
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