UNIVERSIDAD APEC UNAPEC

DECANATO DE INGENIERIA Y TECNOLOGIA

CARRERA INGENIERIA ELECTRICA

MAINTENANCE ENGINEERING CODE: TEC-709

UNIT III TYPES OF MAINTENANCE

PROFESSOR: FRANK NEZ RAMREZ, MSEPE

UNAPEC, MAY 2011

MAINTENANCEENGINEERING(TEC709) Author:Prof.FrankNezRamrez,MSEPE

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UNIT III TYPES OF MAINTENANCE Types of Maintenance

What is maintenance and why is it performed? Past and current maintenance practices in both, the private and government sectors, would imply that maintenance is the actions associated with equipment repair after it is broken. The dictionary defines maintenance as follows: the work of keeping something in proper condition. This would imply that maintenance should be actions taken to prevent a device or component from failing or to repair normal equipment degradation experienced with the operation of the device to keep it in proper working order. The practical operation of a component is time-based function. If we were to graph the failure rate of a component population versus time, it is likely the graph would take the bathtub shape shown in the figure below. In the figure the Y axis represents the failure rate and the X axis is time. From its shape, the curve can be divided into three different zones: infant mortality, useful life, and wear-out periods.

Figure 1: Failure-Time Bathtub Shape Graphic

MAINTENANCEENGINEERING(TEC709) Author:Prof.FrankNezRamrez,MSEPE
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The initial infant mortality period of the bathtub curve is characterized by high failure rate followed by a period of decreasing failure. Many of the failures associated with this region are linked to poor design, poor installation, or misapplication. The infant mortality period is followed by a nearly constant failure rate period, known as useful life. There are many theories on why components fail in this region, most acknowledge that poor O&M often plays significant role. It is also generally agreed that exceptional maintenance practices, applying predictive and preventive elements, can extend the useful life period. The wear-out period is characterized by a rapid increasing failure rate with time. The design life of most equipment requires periodic maintenance. Belts need adjustments, alignment needs to be maintained, proper lubrication on rotating equipment is required, and so on. In some cases, certain components need replacement, (e.g., a wheel bearing on a motor vehicle) to ensure the main piece of equipment (in this case a car) last for its design life. Anytime we fail to perform maintenance activities intended by the equipments designer, we shorten the operating life of the equipment. But, what options do we have? Over the last 30 years, different approaches to how maintenance can be performed to ensure equipment reaches or exceeds its design life have been developed. In addition to waiting for a piece of equipment to fail (reactive maintenance), we have the following types of maintenance: 1. Preventive Maintenance. 2. Predictive Maintenance. 3. Reliability Centered Maintenance.

MAINTENANCEENGINEERING(TEC709) Author:Prof.FrankNezRamrez,MSEPE

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Preventive Maintenance
Preventive maintenance can be defined as follows: Actions performed on a timebased or machine run-based schedule that detect, preclude, or mitigate degradation of a component or system with the benefit of sustaining or extending its useful life through controlling degradation to an acceptable level. Preventive maintenance programs present the following advantages: Increase component life cycle. Promote energy savings. Reduce equipment or process failure. Over 12% to 18% cost savings over reactive maintenance program. Preventive maintenance programs have several advantages over that of a purely reactive program. By performing the preventive maintenance as the equipment designer envisioned, we will extend the life of the equipment closer to design. This translates into dollar savings. Preventive maintenance programs (lubrication, filter change, etc.) will generally run the equipment more efficiently, resulting in more savings. While we will not prevent equipment catastrophic failures, we will decrease the number of failures. Minimizing failures translate into maintenance and capital cost savings.

Predictive Maintenance
Predictive maintenance can be defined as follows: Measurements that detect condition of system degradation, thereby allowing casual stressors to be eliminated or controlled prior to any significant deterioration in the component physical state. Basically, predictive maintenance differs from preventive maintenance by basing maintenance needs on the actual condition of the machine, rather than on some preset schedule. For example, most people change the oil in their vehicles every 3,000 to 5,000 kilometers traveled. This is effectively basing the oil change needs on the equipment run time. No concern is given to the actual condition and performance capability of the oil. It is changed just because it is time for it.
MAINTENANCEENGINEERING(TEC709) Author:Prof.FrankNezRamrez,MSEPE
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If, on the other hand, the operator of the car discounted the vehicle run time and had the oil analyzed at some periodicity to determine its actual condition and lubrication properties, he/she may be able to extend the oil change until the vehicle had traveled 10,000 kilometers. This is the fundamental difference between predictive maintenance and preventive maintenance, where predictive maintenance is used to define needed maintenance tasks based on qualified material/equipment conditions. Some of the advantages of the predictive maintenance are: Increase component operational life/availability. Decrease in equipment or process downtime. Decrease in costs for parts and labor. Improve worker and environmental safety. Promote energy savings. Estimated 8% to 12% maintenance cost savings over preventive maintenance program.

But, it is important to point out some disadvantages: Increase investment in diagnostic equipment. Increase investment in staff training. Savings potential not readily seen by management.

Reliability Centered Maintenance

Reliability Centered Maintenance or RCM can be defined as follows: A process used to determine the maintenance requirements of any physical asset in its operating context. Basically, RCM methodology deals with some key issues not dealt with by other maintenance programs. It recognizes that all equipment in a facility is not of equal importance to either the process or facility safety. It recognizes that equipment design and operation differs and that different equipment will have a higher probability to undergo failures from different degradation mechanisms than others, It also approaches the structuring of a maintenance program recognizing that a facility does not have unlimited financial and personnel resources and that the use of both need to be prioritized and optimized. RCM is a systematic method to evaluate a facilitys equipment and resources to combine them targeting reliability and cost-effectiveness.
MAINTENANCEENGINEERING(TEC709) Author:Prof.FrankNezRamrez,MSEPE
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RCM is highly reliant on predictive maintenance, but also recognizes that maintenance activities in equipment that is inexpensive and unimportant to the facility reliability may best be left to reactive maintenance approach. The following maintenance program utilizes all available maintenance approaches with predominant influence of the predictive maintenance: < 10% Reactive maintenance. 25% to 35% Preventive maintenance. 45% to 55% Predictive maintenance. Advantages: Can be the most efficient maintenance program. Lower costs by eliminating unnecessary maintenance or overhauls. Minimizes frequency of overhauls. Reduces probability of sudden equipment failures. Focuses maintenance activities on critical components. Increases component reliability. Incorporates root cause analysis.

Disadvantages: It has significant start-up cost, training, equipment, etc. Savings potential not readily seen by management.
[Source: O&M Best Practices Guide, Release 3.0, Chapter 5.0]

Cost Related to a Maintenance Program

A maintenance cost estimate is based on two areas of information: The type or classification of the job; and The end use to which the estimate will be put. Classifying the job and obtaining full information about its specifications is the first requisite. It is necessary to know the job priority or urgency, work content, and general conditions under which the work will be performed. How the estimate will be used is the second requisite. Together, these major factors will determine who will do the estimating, how the estimate will be made, the amount of details required, and specific techniques to be followed.
MAINTENANCEENGINEERING(TEC709) Author:Prof.FrankNezRamrez,MSEPE
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What the estimator knows about a job is determined by the degree to which the job is or can be planned before then work is started. Where there is more information, there can be better planning, better estimates, and usually, better costs. Estimates may be properly performed by any of three general groups: foremen, engineers, and planners. Foremen Estimates: Estimates by the maintenance foreman are generally the quickest and easiest to obtain; can be based on limited advance information, and may be made without formal requests or other controls. Estimating by foreman should be limited to situations where it does not interfere with needed supervision and where more detailed procedures are not necessary or practical. Engineering Estimates: The design of major maintenance projects and the selection or design of equipment may require estimates of installation labor costs, as well as purchase prices and contractors quotations. While maintenance foreman or planners may be called in for consultation, the design procedure involved usually require that engineers develop these estimates. Planner Estimates: The maintenance planner gives to the maintenance foreman the source of staff support the foreman needs to develop his/her work. The kind of estimates done by the planner may also vary widely. In fact, flexibility to use various means of estimating to fit different situations is one of the prime advantages of having planners do the estimating. Estimating Techniques for Labor Cost: Some of the techniques applied in the industry or in construction works relay on the following criteria: Judgment: In many cases, judgment based on personal experience is good enough for some particular situations. The main objections to estimates based on personal judgment are fundamentally related to lack of consistency. Example: Labor cost estimation based on judgment for a Diesel engine change of oil and filters: $50.00/per unit. This information is based only in judgement.
MAINTENANCEENGINEERING(TEC709) Author:Prof.FrankNezRamrez,MSEPE

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Slotting (time estimation): Another method is called slotting, in which the job is classified based on a specific time frame. Normally, the slotting procedures apply the comparison with similar jobs (bench marking) to narrow the timing or cost estimates. Example: Labor cost estimation based on slotting for an electrical motor replacement of roll bearings: Men required = 2 men Time required = 1.5 hours Man-Hour required = 2 men x 1.5 hours = 3.0 man-hour Average unit cost of labor = $30.00/man-hour Labor Cost Estimate = 3.0 man-hour x $30.00/man-hour = $90.00 Exercises: 1. Determine the labor cost of a job applying the Slotting method for the change-over of a component of a manufacturing machine, according to the following data: Men required = 3 Time required = 4 hours Average Unit Cost of Labor = $35.00/Man-Hr Man-Hour Required = 3 Men x 4 Hours = 12 Man-Hour Labor Cost Estimates = 12 Man-Hour x $35.00/Man-Hour Labor Cost Estimates = $420.00

2. If the Labor Cost Estimates calculated using the Slotting method is $1,500, and the time required to do the job is 6 hours; determine how many men do you need to finish the job on time. Average Unit Cost of Labor is $50.00/Man-Hour Labor Cost Estimates = $1,500 Time required = 6 hours Average Unit Cost of Labor = $50.00/Man-Hour Labor Cost Estimates = Man-Hour Required x Average Unit Cost of Labor Man-Hour Required = Labor Cost Estimates / Average Unit Cost of Labor = $1,500 / $50.00/Man-Hour = 30 Man-Hour Men Required = 30 Man-Hour / 6 Hours = 5 Men Men Required = 5 Men
MAINTENANCEENGINEERING(TEC709) Author:Prof.FrankNezRamrez,MSEPE

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Standards-per- Unit: The standards-per-unit includes a wide variety of estimating procedures. This method has the advantage of being based on fixed values per unit, which can be reapplied consistently. Example: Labor cost estimation based on standards-per-unit for painting an office building: Labor per square meter of surface = $20.00/m2 Surface to be painted = 2,550 m2 Total labor cost for painting an office building = $20.00/m2 x 2,550 m2 = $5,100.00 Exercises 1. A production machine produce 1,250 components per minute, and the machine operates continuously for 10 hours before it is stopped for maintenance; applying the Standard-per-Unit method, determine the amount of components the machine produced before it was stopped. Unit Production = 1,250 units/min Operating Time = 10 hours = 600 min Total Production = Unit Production x Operating Time = 1,250 units/min x 600 min Total Production = 750,000 units 2. A building has a total surface of 10,500 square feet (ft2), and a plaster worker apply 65 square feet per hour (ft2/hr) of plaster; determine the time required by the plaster worker to finish up the work, applying the Standardper-Unit method. Total Surface = 10,500 ft2 Per Unit Rate of Work = 65 ft2/hr Time Required = Total Surface / Per Unit Rate of Work = 10,500 ft2 / 65 ft2/hr Time Required = 162 hr = 20.25 days

MAINTENANCEENGINEERING(TEC709) Author:Prof.FrankNezRamrez,MSEPE

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Estimating Techniques for Material Cost: Estimating material cost for maintenance and repair works is relatively more precise and direct than estimating labor cost. Purchase of machinery, equipment or construction materials should be generally based on actual bids or quotations from the supplier. A practical method for estimating material is to establish ratios based on labor estimates, as follows: 1) Gather actual material and labor cost data for a large number of jobs. 2) Classify the jobs. 3) Calculate the average ratio of material cost to labor cost for each job classification. Example: Job Classification: Application of plaster on a wall in a construction work Labor cost per square meter = $20.00/m2 Material cost per square meter = $30.00/m2 $30.00/m2 Average Ratio Material to Labor = --------------------------- = 1.5 $20.00/m2

Exercise 1. The Average Ratio Material-to-Labor for an electrical substation construction is 4.50. If the cost of the total labor paid was $195,000; determine the required investment in materials to calculate the direct cost of construction. Average Ratio Material-to-Labor = 4.50 Total Cost of Labor = $195,000 Average Ratio Material-to-Labor = Total Cost of Material / Total Cost of Labor Total Cost of Material = Average Ratio Material-to-Labor x Total Cost of Labor = 4.50 x $195,000 Total Cost of Material = $877,500

MAINTENANCEENGINEERING(TEC709) Author:Prof.FrankNezRamrez,MSEPE

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Estimating Techniques for Overhead Cost: An overhead cost is one which is not directly related to a specific job or project. In maintenance this means items such as salary supervision, storeroom and tool room operations, shop equipment and facilities, and miscellaneous supplies. Additional benefits such as vacation, holiday pay and health insurance are also overhead costs. In order to account for all the costs of operating a maintenance department, some means of prorating these general costs to individual jobs is adopted. Usually this is accomplished by dividing the total overhead cost for a given period by the total maintenance labor hours charged to specific jobs and then establishing an overhead rate per maintenance direct labor hour. Example: Type of Job: Cleaning, drying, and painting the field and armature windings of a 100 MVA synchronous generator. Labor Hour Used = 3,000 man-hour Total Overhead Cost = $90,000.00
$90,000 Total Overhead Cost Overhead Rate = ------------------------------- = ------------------------ = $30.00/man-hour Labor Hour Used 3,000 man-hour [Source: maintenance Engineering Handbook. Fourth Edition. Lindley R. Higgins]

Exercise 1. The overhaul of a Circulating Water Pump in a thermal power station takes a Total Overhead Cost of $49,500, with a Overhead Rate of $90.00/man-hour; calculate the Labor Hour used to conduct that overhaul. Overhead Rate = Total Overhead Cost / Labor Hour Used Labor Hour Used = Total Overhead Cost / Overhead Rate = $49,500 / $90.00/man-hour Labor Hour Used = 550 man-hour

MAINTENANCEENGINEERING(TEC709) Author:Prof.FrankNezRamrez,MSEPE

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