Planned maintenance system (PMS)

Ship Manager Technical is the technical ship management system for both planned and
unplanned maintenance, defect reporting and technical asset and data management. A
Planned Maintenance System streamlines the planning, documentation and
implementation of maintenance work and surveys onboard ship.

Planned Maintenance Systems requirements

Today, there is a minimum requirement that one Planned

Maintenance system must contain:
The description and documentation of the Planned Maintenance

system are to be in the English language.

Reports in Planned Maintenance system should be in English, except

when not suitable for the crew. In that case a brief English summary is

required.
Planned Maintenance program must include equipment manufacturer

requirements.
Inventory content, i.e. items/systems have to be included in the

maintenance program.
Maintenance time intervals, i.e. time intervals at which the

maintenance jobs are to take place.

Maintenance instructions, i.e. maintenance procedures to be followed.
Maintenance documentation and history, i.e. documents specifying

maintenance jobs carried out and their results.

Reference documentation, i.e. performance results and measurements

taken at certain intervals for trend investigations from delivery stage.

Document flow chart, i.e. chart showing flow and filling of maintenance

documents as planning cards, job cards etc.

 Signing instructions, i.e. who signs documents for verification of

maintenance work carried out.

The purpose of the planned maintenance system is:

To ensure that all maintenance is carried out with adequate intervals, and in
accordance with the schedule in the planned maintenance system.

To maintain and keep all engines, machinery and technical components in good
working order at all times, to avoid stoppages and to maintain charter party speed and
consumption requirements.

To avoid interruption and oversight of work by covering all of the work.

To make clear demarcation between onboard and shore maintenance work.

What should be the main objectives of a maintenance plan?

As mentioned before, the main objective of a maintenance plan is to make sure that the
work is done in the least possible time with utmost efficiency and at optimum cost.

Various points mentioned in the ISM code are taken into consideration, along with
companys procedures and manufacturers guidelines.

Other aspects include type of the ship, condition of the ship, age of the ship etc.

How is the maintenance plan made and implemented?

In order to carry out a successful maintenance plan, the following steps are considered
in order to form a strategic approach:

1. Identifying the problem

2. Establishing the clause

3. Proposing solution

4. Evaluating solution

5. Implementing solution

6. Evaluating effectiveness

7. Solving

While developing a maintenance procedure for a particular ship, the shipping company
takes the following points into consideration:

Maintenance guidelines and specifications given by the manufacturer

History of equipment including failures, defects, damagers, and remedial action

Guidelines mentioned in the ISM code

Age of the ship

Third party inspections

Consequences of failure of equipment on safe operation of the ship

Critical equipment and systems

Intervals of maintenance
Considering the above mentioned points, a systematic approach to maintenance is
made. This is necessary to ensure that nothing is missed while carrying out the
maintenance procedure.

Following steps are included in the approach for maintenance procedure:

Establishment of maintenance intervals

Methods and frequency of inspections

Specification of the type of inspection

Type of measuring equipment to be used

Establishment of appropriate acceptance criteria

Assignment of responsibility for inspection activities to appropriately qualified

personnel

Clear definition of reporting requirements and mechanisms

Maintenance interval forms the most important aspect of the maintenance plan.

The maintenance interval decided in the plan is based on the following factors:

Manufactures recommendations and specifications

Predictive maintenance determination techniques

Practical experience of the engineers in operation and maintenance of ship and

its machinery

Historical trends obtained from the results of routine inspections, and in nature
and rate of failures.

The use of the equipment continuous, intermittent, standby, or emergency

 Practical and operational restrictions

Guidelines for internals specified as part of class, convention, administration and

company requirements

Need for regular testing of S/B arrangement

Lastly, following steps are included for writing down the final procedure for planned
inspection routines :

Criteria for inspection

Use of appropriate measuring and testing equipment

Calibration of measuring and testing equipment

The type of inspection and test to be employed visual, vibration, pressure,

temperature, electrical, load, water tightness

Considering the above mentioned points, a systematic and planned maintenance

procedure is made which also forms an integral part of ships planned maintenance
system.

For inspection purpose checklist are often used to ensure that the inspection, test and
maintenance are performed according to the guidelines of manufacturers, shipping
company, and the ISM code.

Most common modules in modern PMS system include:

_ Maintenance (main and essential part of program)
_ Drydocking
_ Hull inspection maintenance program
_ Surveys and certificates class society integration
_ Stock ordering and purchase
_ Stock control (inventory)
_ Safety management
_ Quality management
 _ Crewing management
_ Crew payroll
_ Self-assessment
_ Energy and environmental management
_ Document management systems
_ Enterprise reporting

Types of Maintenance

1. Breakdown maintenance
It means that people waits until equipment fails and repair it. Such a thing could be used
when the equipment failure does not significantly affect the operation or production or
generate any significant loss other than repair cost.

2. Preventive maintenance ( 1951 )

It is a daily maintenance ( cleaning, inspection, oiling and re-tightening ), design to
retain the healthy condition of equipment and prevent failure through the prevention of
deterioration, periodic inspection or equipment condition diagnosis, to measure
deterioration. It is further divided into periodic maintenance and predictive
maintenance. Just like human life is extended by preventive medicine, the equipment
service life can be prolonged by doing preventive maintenance.
2a. Periodic maintenance ( Time based maintenance - TBM)
Time based maintenance consists of periodically inspecting, servicing and cleaning
equipment and replacing parts to prevent sudden failure and process problems.

2b. Predictive maintenance

This is a method in which the service life of important part is predicted based on
inspection or diagnosis, in order to use the parts to the limit of their service life.
Compared to periodic maintenance, predictive maintenance is condition based
maintenance. It manages trend values, by measuring and analyzing data about
deterioration and employs a surveillance system, designed to monitor conditions
through an on-line system.

3. Corrective maintenance ( 1957 )

It improves equipment and its components so that preventive maintenance can be
carried out reliably. Equipment with design weakness must be redesigned to improve
reliability or improving maintainability

4. Maintenance prevention ( 1960 )

It indicates the design of a new equipment. Weakness of current machines are
sufficiently studied ( on site information leading to failure prevention, easier
maintenance and prevents of defects, safety and ease of manufacturing ) and are
incorporated before commissioning a new equipment.

Types of Maintenance Procedures

1) Preventive or Scheduled Maintenance System

It is famously known as the PMS or Planned Maintenance System. In this type of

system the maintenance is carried out as per the running hours like 4000 hrs, 8000 hrs
etc., or by the calendar intervals like 6 monthly, yearly etc. of the machinery. The
maintenance is carried out irrespective of the condition of the machinery. The parts have
to be replaced if it is written in the schedule, even if they can be still used.

2) Corrective or Breakdown Maintenance

In this system the maintenance is carried out when the machinery breaks down. This is
the reason it is known as the breakdown maintenance. This is not a suitable and good
method as situations may occur wherein the machinery is required in emergency. The
only advantage of this system is that the working of machinery parts is used to its full life
or until it breaks. This system might get costly as during breakdown several other parts
may also get damaged.

3) Condition Maintenance system

In this system the machinery parts are checked regularly. With the help of sensors etc.
the condition of the machinery is accessed regularly and the maintenance is done
accordingly. This system requires experience and knowledge as wrong interpretation
may damage the machinery and lead to costly repairs which may not be acceptable by
the company.