WHAT ARE THE DIFFERENT TYPES OF MAINTENANCE SYSTEMS.
Maintenance Management
Management characterises the process of
leading and directing all or part of an organization, often a business one, through
the deployment and manipulation of resources (human, financial, material,
intellectual or intangible).
One can also think of management functionally as the
action of measuring a quantity on a regular basis and adjusting an initial plan
and the actions taken to reach one's intended goal. This applies even in
situations where planning does not take place. Situational management may
precede and subsume purposive management.
Maintenance management will therefore characterise the process of leading
and directing the maintenance organization. Before describing this process, let
us make sure that we understand what a maintenance organization, with the
resources belonging to it, is pursuing.
Maintenance is defined as the combination of all technical,
administrative and managerial actions during the life cycle of an item intended
to retain it in, or restore it to, a state in which it can perform the required
function (function or a combination of functions of an item which are
considered necessary to provide a given service).
This definition clarifies the objective of maintenance and can help us to
understand what part of an organization is, somehow, devoted to maintenance.
we can define maintenance management as follows :
"All the activities of the management that determine the maintenance
objectives or priorities (defined as targets assigned and accepted by the
management and maintenance department), strategies (defined as a
management method in order to achieve maintenance objectives), and
responsibilities and implement them by means such as maintenance
planning, maintenance control and supervision, and several improving
methods including economical aspects in the organization."
the objectives of the MMS
A. Optimize the use of available funds, personnel, and facilities and equipment through effective maintenance management methods.
B. Provide accurate data for maintenance and construction program decisionmaking.
C. Systematically identify maintenance needs and deficiencies and capital improvement needs at all field stations.
D. Determine the unfunded maintenance backlog for the Service.
E. Establish field station, Regional, and national maintenance and construction project priorities.
F. Enable preparation of Service maintenance and construction budget requests using systematic, standardized procedures.
G. Monitor and document corrective actions, project expenditures, and accomplishments.
H. Conduct comprehensive condition assessments of all Service real property and personal property valued at $50,000 or greater.
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Various types of maintenance strategies
1. Reactive Maintenance
Reactive maintenance is basically the "run it till it breaks" maintenance mode. No actions or
efforts are taken to maintain the equipment as the designer originally intended to ensure design life is
reached.
Advantages to reactive maintenance can be viewed as a double-edged sword. If we are dealing
with new equipment, we can expect minimal incidents of failure. If our maintenance program is
purely reactive, we will not expend manpower dollars or incur capitol cost until something breaks.
Advantages
• Low cost.
• Less staff.
Disadvantages
• Increased cost due to unplanned downtime of
equipment.
• Increased labor cost, especially if overtime is
needed.
• Cost involved with repair or replacement of
equipment.
• Possible secondary equipment or process damage
from equipment failure.
• Inefficient use of staff resources
2. Preventive Maintenance
Preventive maintenance can be
defined as follows: Actions performed on
a time- or machine-run-based schedule
that detect, preclude, or mitigate degradation
of a component or system with the
aim of sustaining or extending its useful
life through controlling degradation to an
acceptable level.
Advantages
• Cost effective in many capital intensive processes.
• Flexibility allows for the adjustment of maintenance
periodicity.
• Increased component life cycle.
• Energy savings.
• Reduced equipment or process failure.
• Estimated 12% to 18% cost savings over reactive
maintenance program.
Disadvantages
• Catastrophic failures still likely to occur.
• Labor intensive.
• Includes performance of unneeded maintenance.
• Potential for incidental damage to components in
conducting unneeded maintenance.
3. Predictive Maintenance
Predictive maintenance can be defined as follows: Measurements that detect the onset of a degradation
mechanism, thereby allowing causal stressors to be eliminated or controlled prior to any significant
deterioration in the component physical state. Results indicate current and future functional
capability.
Basically, predictive maintenance differs
from preventive maintenance by basing
maintenance need on the actual
condition of the machine rather than on
some preset schedule. You will recall that
preventive maintenance is time-based.
Activities such as changing lubricant are
based on time, like calendar time or
equipment run time. For example, most
people change the oil in their vehicles
every 3,000 to 5,000 miles traveled. This
is effectively basing the oil change needs
on equipment run time. No concern is
given to the actual condition and performance
capability of the oil. It is changed
because it is time. This methodology
would be analogous to a preventive maintenance
task. 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 miles. This is the fundamental difference between predictive maintenance and preventive
maintenance, whereby predictive maintenance is used to define needed maintenance task
based on quantified material/equipment condition.
The advantages of predictive maintenance are many. A well-orchestrated predictive maintenance
program will all but eliminate catastrophic equipment failures. We will be able to schedule
maintenance activities to minimize or delete overtime cost. We will be able to minimize inventory
and order parts, as required, well ahead of time to support the downstream maintenance needs. We
can optimize the operation of the equipment, saving energy cost and increasing plant reliability. Past
Advantages
• Increased component operational life/availability.
• Allows for preemptive corrective actions.
• Decrease in equipment or process downtime.
• Decrease in costs for parts and labor.
• Better product quality.
• Improved worker and environmental safety.
• Improved worker moral.
• Energy savings.
• Estimated 8% to 12% cost savings over preventive
maintenance program.
Disadvantages
• Increased investment in diagnostic equipment.
• Increased investment in staff training.
• Savings potential not readily seen by management.
4.Reliability Centered Maintenance
RCM: "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. In a nutshell, RCM
is a systematic approach to evaluate a
facility's equipment and resources to best
mate the two and result in a high degree
of facility reliability and cost-effectiveness.
RCM is highly reliant on predictive maintenance
but also recognizes that maintenance
activities on equipment that is
inexpensive and unimportant to facility
reliability may best be left to a reactive
maintenance approach. The following
maintenance program breakdowns of
Advantages
• Can be the most efficient maintenance program.
• Lower costs by eliminating unnecessary maintenance
or overhauls.
• Minimize frequency of overhauls.
• Reduced probability of sudden equipment failures.
• Able to focus maintenance activities on critical
components.
• Increased component reliability.
• Incorporates root cause analysis.
Disadvantages
• Can have significant startup cost, training, equipment,
etc.
• Savings potential not readily seen by management.
How Tero-technology is related to maintenance management, Discuss
The term "technology" to refer to the study of the costs associated with an asset throughout its life cycle - from acquisition to disposal. The goals of this approach are to reduce the different costs incurred at the various stages of the asset's life and to develop methods that will help extend the asset's life span.
Terotechnology uses tools such as
-net present value,
-internal rate of return and
-discounted cash flow in an attempt to minimize the costs associated with the asset in the future.
These costs can include engineering, maintenance, wages payable to operate the equipment, operating costs and even disposal costs.
Also known as "life-cycle costing".
For example, let's say an oil company is attempting to map out the costs of an offshore oil platform. They would use terotechnology to map out the exact costs associated with assembly, transportation, maintenance and dismantling of the platform, and finally a calculation of salvage value.
This study is not an exact science: there are many different variables that need to be estimated and approximated. However, a company that does not use this kind of study may be worse off than one that approaches an asset's life cycle in a more ad hoc manner.
THIS APPROACH HELPS TO OBTAINING MAXIMUM BENEFIT
FROM THE PHYSICAL ASSETS. THIS INVOLVES
-systematic application of engineering,
-financial and management expertise in the assessment of the life cycle
impact of an acquisition [ plant/equipment/machines etc ] on the
revenues and expenses of the acquiring organization.
PRACTICE OF of terotechnology is a continuous CYCLE that begins with the DESIGN and SELECTION of the REQUIRED item, follows through with its INSTALLATION,COMMISSIONING ,OPERATION , and MAINTENANCE until the item's REMOVAL and DISPOSAL and then restarts with its REPLACEMENT .
An additional answer
Some engineers add proactive maintenance instead of reliability centered maintenance .
Proactive maintenance is combination of reactive ,preventive and predictive maintenance and shares advantages with each of them.
Proactive approach has gained much popularity in maintenance of plants and installations.
Preventive maintenance
Corrective Maintenance
Predictive Maintenance
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The old concept of maintenance was to attend a machine after it has failed or stopped functioning. But now some more concepts have been identified and applied in the realm of MAINTENANCE. It is no more ' work after failure". According to author of one article, the following are the basics types of maintenance programs. 1) Reactive maintenance or corrective maintenance or Break down maintenance 2) Preventive maintenance 3) Predictive maintenance 4) Proactive maintenance The author gave sufficient details of each of above types in said article. See Sources and Related Links for more information. Ter-technology is economic management of assets. Maintenance is a part of tero-technology.
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