MAINTENACE STRATEGIES

Priyanka Mishra

WHAT IS MAINTENANCE STRATEGY? Maintenance Strategy is a long-term plan, covering all aspects of maintenance management which sets the direction, and contains firm action plans for achieving a desired future state for the maintenance function.
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WHY MAITENANCE STRATEGY IS REQUIRED?

For Time-based or performance-based maintenance plans in any organisation, we can implement strategy-based maintenance. By using maintenance strategy we can1.Reduce maintenance plan creation time 2.Update scheduling information easily.
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Maintenance Strategy

Planned

Unplanned (Failure based)

Zero Hour Maintenance (annual shutdown)

Predictive Maintenance

Preventive Maintenance

Reliability Centered Maintenance

Corrective Maintenance

Breakdown Maintenance

Condition Based Maintenance

Time based Maintenance

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Corrective Maintenance

Corrective Maintenance refers to action only taken when a system or component failure has occurred .It is thus a retro-active strategy. It is of minor nature.
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Breakdown Maintenance
Breakdown maintenance involves the repair or replacement of equipment and components after they have failed.

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Preventive Maintenance
In Preventive Maintenance, equipment is repaired and serviced before failure occur. The frequency of maintenance activities is predetermined by schedules. Preventive maintenance aims to eliminate unnecessary inspection and maintenance tasks, to implement additional maintenance tasks when and where needed and to focus efforts on the most critical items.
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A)Time Based Maintenance(TBM)

For time-based maintenance planning, maintenance is performed at specific intervals, for example, every two months or every six months.

B)Conditional Based Maintenance(CBM)

Direction of maintenance actions based on indications of equipment health as determined from non-invasive measurement of operation and condition indicators. CBM allows preventative and corrective actions to be optimized by avoiding traditional calendar or run based maintenance.
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Predictive Maintenance
Predictive maintenance refers to maintenance based on the actual condition of a component. Maintenance is not performed according to fixed preventive schedules but rather when a certain change in characteristics are noted. Corrosion/erosion sensor supplying diagnostic information on the condition of a system or component play an important role in this maintenance strategy.
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Zero hour Maintenance(Overhauling)

The set of tasks whose goal is to review the equipment at scheduled intervals before appearing any failure, either when the reliability of the equipment has decreased considerably so it is risky to make forecasts of production capacity . This review is based on leaving the equipment to zero hours of operation. These reviews will replace or repair all items subject to wear. The aim is to ensure, with high probability, a good working time fixed in advance.
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Reliability Centered Maintenance(RCM)

RCM involves the establishment or improvement of a maintenance program in the most cost effective and technically feasible manner. It utilizes a systematic, structured approach that is based on the consequences of failure. As such it represents a shift away from time-based maintenance tasks and emphasizes the functional importance of the system components and their failure/maintenance history.
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How to implement Maintenance Strategies

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Identify the Equipment's on the basis of criticality

Critical Equipment (which affects the production and do not have its stand by)

Semi Critical(which partially affects the production but have its stand by)

Not Critical(which do not affect the production directly)

Failure Mode and effects analysis (FEMA) of the critical equipment's

Rapid Failure Mode and effects analysis (FEMA) of the equipment's by reviewing most significant failures

General analysis by equipment type or activity

Define type of Maintenance strategy required for the equipment

Define type of Maintenance strategy required for the equipment

Define type of Maintenance strategy required for the equipment

Define the Maintenance frequency equipment wise

Define the Maintenance frequency equipment wise

Define the Maintenance frequency equipment wise

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How to determine Maintenance frequency

Equipment Type

Work order history and knowledge By calculating Mean time between failure(MTBF) Manufacturers recommendation

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Preventive Maintenance Activity Flowchart

Identify the major equipment's whose PM is to be done Return the PTW after PM and housekeeping of the area Trial Out of the equipment will be done by operation in the presence of maintenance to ensure the work, otherwise reissue of the PTW .

Prepare the work instruction /SOP for the equipment and resource planning

If Equipment is released and PTW issued then carry out the PM otherwise reschedule the PM .

Then record the PM data in SAP for future reference and database.

Scheduling and Release of Maintenance schedule by Maintenance Department.

Request to Operation department for release of equipment for PM.

Analysis of data and planning for improvement and incorporate changes in work instruction and SOPs if required.

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Zero Hour Maintenance( Annual Shutdown) Activity Flowchart

Planning for annual shutdown on the basis of defect reporting and database. Return the PTW and trial run of equipment by operation in presence of maintenance
If the equipment performance is satisfactory then job is complete otherwise reissue the PTW and carry our the job

Request for release of equipment to operation and take PTW

Housekeeping of area after completion of job.

After completion of job Recording of data in SAP for history and reference.

Preparation related to safety and environment

Opening, inspecion and rectification of problem

Analysis of the data and planning for improvement and incorporate changes in SOPs if required and spares planning as per the requirement.

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Breakdown Maintenance Activity flow chart

Receipt of defects through defect reporting or on phone. Return PTW and trial run of equipment by operation in presence of maintenance If equipment performance is OK else reissue of PTW.

Identify if the defect is chronic or Sporadic?

Carryout inspection, rectification of defect and housekeeping of area.

Recording of data in SAP. Analysis of data and planning for improvement

If the defect can be rectified online or not

If yes then Take PTW with proper isolation else plan for outage of the equipment.

Incorporate changes in work instruction and SOPs.

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Results For Measurement and controls of Maintenance Strategy

Repair and Maintenance cost per unit.
Breakdown % of the equipment. Number of rework on the equipment. Availability of the equipment. MTTR(Mean Time To Repair) MTBF(Mean Time Between Failure)

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Thank You..