amm_training course.ppt

Advanced MaintenanceManagement

Dr. Waleed Tahawy

Objectives

• Industry today is in a fight to survive. Competition is found not only on a domestic level, but also on international levels. In an effort to survive, all forms of production analysis, product reviews, and material reviews are made and periodically checked. Statistical process control is only one of the new methods used to reduce operational costs. However, one area many industries are now turning their attention toward is the maintenance function.

Objectives

• Cost reduction in maintenance does not necessarily mean a reduction in service or in the quality of service. It means a better control of the maintenance organization and the related areas. To properly control the maintenance of any facility, information is required to analyze what is occurring. Manually, this requires a tremendous amount of effort and time. In recognition of this, many of the progressive companies are developing and using computer programs geared toward control of the maintenance organization. These systems are often referred to as computerized maintenance management systems (CMMS).

What is Maintenance?

• Maintenance - any activity carried out on an asset in order to ensure that the asset continues to perform its intended functions, or to repair the equipment. Note that modifications are not maintenance, even though they may be carried out by maintenance personnel.

What is Maintenance?

• Maintenance is war. Your enemies are the triumvirate of breakdown, deterioration, and all types of unplanned events. Your soldiers are the maintenance department and as many civilians as you can recruit. The civilians you protect are production workers, office workers, drivers, and all the other users of your organization’s assets.

• Keeping equipment's available, reliable and cost optimized.

Asset ?

• Asset - unlike in the accounting definition, in maintenance this is commonly taken to be any item of physical plant or equipment.

• It is the basic unit of maintenance.

Asset Management ?

• Asset Management - the systematic planning and control of a physical resource throughout its life. This may include the specification, design, and construction of the asset, its operation, maintenance and modification while in use, and its disposal when no longer required.

Maintenance Function ?

• The maintenance department has a more involved list of functions or responsibilities. These can be grouped into five main areas:-

1. Maintenance of existing equipment.

2. Equipment inspection and services.

3. Equipment installation.

4. Maintenance storekeeping.

5. Craft administration.


1. Maintenance of Existing Equipment

•Maintaining existing equipment is the basic reason for the department.

•The maintenance group will make repairs to the production equipment as quickly and economically as possible. To prevent rapid wear of the equip ment, the group should utilize cost-effective preventive maintenance programs.

•To perform these tasks as efficiently and cost effectively as possible requires the utilization of a trained workforce and the use of modern tools and maintenance methods that are available.

•However, performing all of the above tasks depends on one im portant item accurate record keeping. Without accurate re cords, it will not be possible to complete the assigned tasks in a timely and cost-effective manner.


2. Equipment Inspections and Service

•This task will require the engineer or manufacturer to determine the proper lubricant for the equipment. In addition to the type of lubricant, the proper amount and time intervals of application of the lubricant are necessary. The inspections are required to ensure that the equipment is in safe operating condition and is being serviced in a timely manner.

•Some installations will require that the operational personnel do some routine lubrication and servicing. Even where this is a common practice, the maintenance department should oversee the completion of the tasks.


3. Equipment Installation

•This responsibility varies from industry to industry and depends on the size of the installation and the maintenance workforce.

•Some industrial facilities that require constant equipment changeover may have an installation department.

•When large installation projects occur in some industries without the necessary workforce, outside contractors are used to supply the needed manpower.


4. Maintenance Storekeeping•This responsibility of the maintenance group involves the receiving and distribution of the spares necessary for the repair and upkeep of the plant equipment. •There are several important tasks involved in this responsibility. The first is recording the necessary spares for each piece of equipment. With all of the spares recorded, the maintenance group has the responsibility of setting the inventory level for each part. As the spares are used, the replacements will have to be ordered.•The ordering process is important to prevent material outages in the stores. Material outages could result in production delays, if equipment breakdowns occur and no replacement parts are available. Keeping the stores inventory level as low as possible will prevent tying up capital investments in spares.


5. Craft Administration

•This is the responsibility of controlling the manpower used by the maintenance department.

•The most cost-effective way of determining the size of the workforce is the work in the maintenance backlog. By looking in the backlog, the number of employees for each craft area can easily be determined. As programs are changed and equipment is added or deleted from a department, the workforce can be adjusted as necessary.

•The responsibility for providing the necessary tools and supplies for the crafts is also included in this area.

Maintenance Objectives

1. To keep the maintenance cost per production item produced as low as possible.

2. To keep the quality of the product very high.

3. To keep the downtime for critical equipment as low as possible.

4. To keep maintenance cost as low as possible for non-critical equipment.

5. To provide and maintain adequate facilities.

6. To provide effective and trained supervision.

What is Management?

Art of doing what is possible out of what is available. Sharing in overheads that leads to unity of goal. Coordination of different tones in a harmony. Guaranty of never being caught in a surprise condition.

Maintenance Management

Maintenance Management is defined as the organization of maintenance within an agreed policy.

Maintenance Policy is a statement of principle used to achieve maintenance objectives and guide Maintenance Management decision making.

Maintenance Factors

• Design• Fabrication• Storing & Transporting• Installation & Commissioning• Operation• Maintenance• Management

Maintenance Planning & Scheduling

Planning is the process in a set frame of time ?

Planning Components:

• Clear tasks/Activities

• Estimates of Resources

• Time Frame for each task

• Critical Path

• Computer Software


• Maintenance Types (Strategies)Maintenance Types (Strategies)

1. Breakdown Maintenance

2. Scheduled Shutdown Maintenance

3. Preventive Maintenance

4. Predictive Maintenance



1- Breakdown Maintenance (BM)

An Equipment Maintenance Strategy, where no routine maintenance tasks are performed on the equipment. The only maintenance performed on the equipment is Corrective Maintenance, and then only after the equipment has suffered a failure. Also described as a Run-to-Failure strategy.



1- Breakdown Maintenance (BM)

- Is generally the economic approach for equipment which causes no significant safety hazards or loss of revenue and suffers little consequential damage on breakdown.

- Ex: small pipe work leaks and non critical mechanical, electrical and instruments faults.


• Maintenance Types (Strategies)Maintenance Types (Strategies)Corrective Maintenance (CM) - It is the measure of Preventive Maintenance and

Predictive Maintenance success and effectiveness.- Using the established protocols, training and

planning of Preventive Maintenance in conducting corrective maintenance tasks.



2- Scheduled Shutdown Maintenance (SSM)-One of the oldest strategy for maintenance.

-There will be a situation in which scheduled shutdown maintenance is required. This may be due to regulation, essential inspections, major cleaning and repair work, which for safety or technical reasons, cannot be carried on stream.

-Scheduling of down time to be arranged with production department according to production plane.



2- Scheduled Shutdown Maintenance (SSM)-Modes:

Separate Mode (SSM is executed every plant, separately.

Plant Group Mode: All the complex is divided into a few plants groups.

Whole refinery mode.



3- Preventive Maintenance (PM)-An equipment maintenance strategy based on replacing, overhauling or remanufacturing an item at a fixed interval, regardless of its condition at the time. Scheduled Restoration tasks and Scheduled Discard tasks are both examples of Preventive Maintenance tasks-It was introduced for the first time in 1950s from USA.



3- Preventive Maintenance (PM)

-Should only be applied where the probable cost of lost revenue and/ or consequential damage resulting from failure scientifically exceeds the cost of such preventive maintenance work and associated down time.

-Suitable application for preventive maintenance , typically would be large, high speed rotating machinery, un spared unit charge pumps, condensers and coolers prove to salt plugging, electrical switch gear, motor and critical instrumentation.


• Maintenance Types (Strategies)Maintenance Types (Strategies)Necessity and Benefit of Applying PM Program.

Availability of information Trend tracking Prevention of sudden failure Optimizing equipment performance Managing the manpower Minimizing the inventory stock


• PM AdvantagesPM Advantages1. Increase Availability

2. Convenient Performance

3. Balance Workloads

4. Overtime Reduction

5. Increase Production Revenue

6. Decrease Standby Equip

7. Increase Quality

8. Reduction Spare Parts

9. Pre-Action Instead Of Re-Action

10. Increase Safety

11. Standardize Procedures


• PM PM DisadvantagesDisadvantages1. Possible Damage Exposing

2. Great Number Of Parts

3. Increase Initial Cost

4. Failure In New Parts

5. More Frequent Access to Equip

Maintenance Planning & SchedulingJustifying PM ExpenditureJustifying PM Expenditure

•Maintenance Costing ReasonsMaintenance Costing Reasons1.Maint. Cost Drivers

2.Budget Preparation

3.New Equip./ Systems Design Input

4.LCC Study Input (Life Cycle Cost)

5.Costs Control

6.Equip. Replacing Decision

7.Optimum PM Policies

8.Competing Maintenance

9.Upper Management Feedback

10.Productivity Improvement


• Maintenance Cost Influence FactorsMaintenance Cost Influence Factors1. Company Policy

2. Equip. Condition

a. Age

b. Type

c. History

3. Operators Experience

4. Maintenance Manpower Skills

5. Operation Environment

6. Type Of Services


• Maintenance Budget TypesMaintenance Budget Types1. Operating Budget:

a. For Coming Year

b. For Every Department

c. Labor, Material & Overhead

d. PM, Semi-annual Shutdown

e. Overhauls

f. Minor Modification

2. Project Budget:

a. Major Capital Equip./Systems

b. Construction Projects

c. Project Labor, Material & Overheads


• Budget Preparation ApproachBudget Preparation Approach

1. Historical Approach

2. Zero Based Approach


1.1. Historical ApproachHistorical Approach

a. Depends Upon History

b. Experience Of Years

c. Cost Estimation Changes

d. Justifying Only Differences

e. Advantages

1. Efficient

2. Rational

3. Less Efforts

4. Small amount Paper Work

f. Disadvantages

1. Past Errors Tend To Ineffective


2.2. Zero Based Budget ApproachZero Based Budget Approach

a. Start From Ground

b. Priority Grouping

c. Justify All Items Current Requirements

d. Priorities vs Availability



• Zero Based CategoriesZero Based Categories

a. Expenditure Required By Law

b. Expenditure Not Required By Law

c. New (First-Time) Budget Item



• Advantages

a. Better Use Of Available Fund

b. Clear Objectives All Levels

c. More Logic & Direct Process

• Disadvantages

More Time, More Effort And Documents


• Budget Preparation StepsBudget Preparation Steps

• Collect, Estimate & Calculate

• Expenses For :

• Important Variables LaborMaterialsOverheads


• Budget Preparation StepsBudget Preparation Steps1. Collect Information Trend Last Years

2. Operations Plans Input

3. Sales By Product & Department

4. Maintenance Labor Hours by Skills & Dep.

5. High Repair Cost Equipment

6. Estimate Material by Department

7. High Volume, High Cost

8. Estimate Overhead Expense

9. Distribute Expenses By Weeks & Months

10. Establish Cumulative Cost Chart For Variables (Labor, Material & Overheads)

11. Update Individual & Total Cost Chart


Maintenance Labor Cost EstimationMaintenance Labor Cost Estimation

Cem = LR (1 + BR) TAH

Cost Per Employee

Labor Rate$/hr

Benefit Ratio

Total Annual Hours


Total Labor CostTotal Labor Cost

TLC = Cem N

Total Labor Cost Number Of Employees

Cost Per Employee


Total Labor CostTotal Labor Cost

TLC = Cem N

Number Of Employees40

Cost Per Employee$ 36,000

TLC = $1,440,000


Example Example

Cem = LR (1 + BR) TAH

Labor Rate $ 15/ hr

Benefit Ratio 0.2

Total Annual Hours 2000 hr

Cost Per Employee= $36,000


Standard Hourly Cost EstimationStandard Hourly Cost Estimation

Csh = PD X FBFPHP + EPHP

Cost Per Standard Hour Produced

Planned HoursProduced

Payroll $ Per Period

Equivalent Planned Hours Produced

Fringe Benefit Factor


Standard Hourly Cost EstimationStandard Hourly Cost Estimation


• Major Steps of Setting up a PM ProgramMajor Steps of Setting up a PM Program Collecting the equipment’s to be maintained

and classifying them. Establishing common standard procedures. Specifying the tools. Specifying the spare parts. Sharing departments. Manpower. Time Scheduling and due dates resolution.



4- Predictive Maintenance (PDM) (Condition Monitoring)4- Predictive Maintenance (PDM) (Condition Monitoring)

-An equipment maintenance strategy based on measuring the condition of equipment in order to assess whether it will fail during some future period, and then taking appropriate action to avoid the consequences of that failure. The condition of equipment could be monitored using Condition Monitoring, Statistical Process Control techniques, by monitoring equipment performance, or through the use of the Human Senses. The terms Condition Based Maintenance, On-Condition Maintenance and Predictive Maintenance can be used interchangeably.



4- Predictive Maintenance (PDM)4- Predictive Maintenance (PDM)

-Was introduced around 1970 to improve the defect of over maintenance that preventive maintenance inherently held.

-It is the application of measurement techniques, usually on-stream, designed to provide information on the current condition of a piece of equipment or system so as to allow the timing extent of preventive maintenance to be decided on rational basis.




-Includes corrosion measurement activities by using ultrasonic test, radiograph test, Corroso Meter, …etc, that were called “On Stream Inspection” (OSI), as well as rotating machinery diagnosis activities using vibration and noise analysis, etc….

-Predictive maintenance indicates generally only the diagnosis, and if deterioration are detected in diagnosis and consequently overhaul is requested the execution of repair will be arranged in schedule of Preventive Maintenance.




-Analysis Method

• Trend Analysis

• Pattern Recognition

• Data Comparison

• Tests Against Limits & Ranges

• Multiple Technologies

• Statically Process Analysis



• Technologies

1.Purpose

2.Techniques

3.Applications

4.Effects

5.Equipment

6.Operators

7.Training

8.Cost



• Analysis

1.Vibration Analysis

2.Thermograph

3.Ultrasound

4.Lubrication Analysis

5.Wear Particles

6.Electrical Condition monitoring

7.Reliability Condition Monitoring

8. RCM


4- Predictive Maintenance (PDM) Technologies4- Predictive Maintenance (PDM) Technologies

Technologies 1-Vibration 2-Thermograph 3- Ultra Sound

20,000-70,000 25,000-70,000 1000 - 8000

Vendor, VI

Vib.Group, High

Page 23

15 Causes

Rot. Eq., Structu.

Freq. Torsion

Noise, Failure

Cont, N Cont, Deep

HE, E.Dist, Pipe, HVAC

Page 25

Therm., System

No Group Need

NDT

Page 24 Noise

Frequency

Steam Plants

Leak, Flow

US, Vib monit.

No Group Need

Available


• 4- 4- Predictive Maintenance (PDM)Predictive Maintenance (PDM)VIBRATIONVIBRATION

Stationary EquipmentStationary EquipmentRotating EquipmentRotating Equipment


4- 4- Predictive Maintenance (PDM)Predictive Maintenance (PDM)Vibration CharacteristicsVibration Characteristics

Periodic Oscillating Motion

• Distance

• Speed

• Acceleration

• Frequency


4- 4- Predictive Maintenance (PDM)Predictive Maintenance (PDM)Vibration MeasuringVibration Measuring

Rotor (rpm) Directions (V-H-A) Vibration Displacement (mils , microns) Vibration Velocity (ips , mm/s) Vibration Frequency (CPM, HZ) Vibration Acceleration (g)


4- 4- Predictive Maintenance (PDM)Predictive Maintenance (PDM)Vibration CausesVibration Causes

1. Mechanical Looseness (cpm = 2 rpm) Vertical

2. Unbalance (cpm = 1 rpm) Radial

3. Misalignment (cpm = 2 rpm) Axial

4. Electrical (cpm = Sync.)

5. Roller Bearing (cpm = Balls x rpm)

6. Oil Whirl (cpm = 0.5 rpm)

7. Gears (cpm = Teeth x rpm)

8. Pumps (cpm = Blades x rpm)

9. Natural Frequency Resonance (Critical Speed)


4- 4- Predictive Maintenance (PDM)Predictive Maintenance (PDM)Faults Rate %Faults Rate %

1. Misalignment 35 %

2. Unbalance 30 %

3. Roller Bearing 7 %

4. Electrical 5 %

5. Journal Bearing 5 %

6. Mechanical Looseness 4 %

7. Gears 4 %

8. Critical Speed 4 %


4- 4- Predictive Maintenance (PDM)Predictive Maintenance (PDM)Vibration QualityVibration Quality Vibration Quality Vibration Velocity

IPS mm/sec

Extremely Smooth < 0.005 <0.125

Very Smooth 0.005 0.125

Smooth 0.009 0.250

Very Good 0.019 0.500

Good 0.036 1.000

Fair 0.075 2.000

Slightly Rough 0.150 4.000

Rough 0.300 8.000

Very Rough 0.600 16.00

Extremely Rough 1.200 32.00


Reliability Condition Monitoring RCMReliability Condition Monitoring RCM

Equipment Conditions Data+

Maintenance Experience

Planners

Designers Maintenance ManagersManufacturers

Craftsmen

Continuous Feedback


Reliability Condition Monitoring RCMReliability Condition Monitoring RCM

Increase Reliability

Fewer Failure

Greater Availability

Lower Maintenance Cost


• Maintenance Types (Strategies)Maintenance Types (Strategies) Unit Run lengths and Shutdown Duration:Unit Run lengths and Shutdown Duration:

- Process unit runtime should be established, within the constraints of safety and legal requirements on the basis of maximizing the profitability of operation.

- It is normally necessary for planning purposes to fix a schedule for the shutdown of process units .

- Similarly shutdown durations should be set at an optimum which balance profit lost during down time against the cost of additional resources required to reduce such downtime.


• Maintenance Types (Strategies)Maintenance Types (Strategies)Emergency Maintenance:Emergency Maintenance:- All works should require a formal work order.- Emergency maintenance and critical maintenance

(work needed immediately or within 24 hours) is seldom planned.


• PlanningPlanning- Planning can be accomplished by the supervisor if

there are relatively few maintenance personnel.- If there are more than 20 craftsmen, planning is

best done by separate maintenance planners, otherwise the foremen have a tendency to do paperwork when they could more profitably spend their time in supervising and directing the work of the craftsmen.


• Type of Work to be planned:Type of Work to be planned:- Emergency maintenance and critical maintenance

(work needed immediately or within 24 hours) is seldom planned.

- These request are of short duration and are performed so quickly that there is no time to plan them.

- These types of work orders should not be considered in planning functions


• Type of Work to be planned:Type of Work to be planned:- Normal corrective or routine work orders should

be the primary consideration of the planning function.

- These work orders are received and placed in work backlog.

- As the workforce and materials become available to carry out the work, it is scheduled.

- Included in this type of work are preventive and predictive maintenance work orders.


• Type of Work to be planned:Type of Work to be planned:- The other group of work requests that can be

planned are the shutdown, turnaround, or the outage work orders.

- For this type of work, it is important that the equipment be shut down and overhauled in the shortest possible time.

- Only by accurate estimating and scheduling of these work requests can the shutdown be successful.


• How to Plan Maintenance Work :How to Plan Maintenance Work :- Effective planning requires the planners to be

skilled and knowledgeable in the craft area they are planning; therefore, supervisors or top craftsmen will make the best planners.

- If an inexperienced individual is promoted to planner, the results of the planning program will not be satisfactory. Instead of increasing productivity, you may find productivity decreasing.


• How to Plan Maintenance Work :How to Plan Maintenance Work :- The planning begins once the work order is approved by

management.

- It is then assigned to the planner, who carefully studies the job.

- The planner must decide the following:-

1. The crafts required

2. The time required

3. The materials required, and

4. Whether outside help in the form specialists, contractors, or special rental equipment is required.


• How to Plan Maintenance Work :How to Plan Maintenance Work :- When the planner is deciding on the required

crafts, he must also decide not only the number of craftsmen, but also the skill level required.

- The time estimate for work order is important. If there is no time estimate, you will never know the man-hours of work that is in the crafts backlog. Without this information, you can never accurately determine the proper staffing levels for your plant.


• How to Plan Maintenance Work :How to Plan Maintenance Work :- The material required for the work order will

determine whether it can be scheduled.

- If the necessary materials are not available and the work order is scheduled, the craftsmen will lose productivity looking for the spare parts and waiting for supervisor to find them work that can be performed.

- It is also necessary to plan the materials so that an accurate estimate of the cost of the work order can be obtained.


• How to Plan Maintenance Work :How to Plan Maintenance Work :- The miscellaneous items to be planned are important to

proper completion of the work order.- If special skills are required from outside source, the in-

house craftsmen may not be able to complete the work order quickly or with necessary quality.

- Also, if special tools or equipment are required, it would be pointless to schedule the work order without them.

- Once the work order is planned and scheduled, the planner should be available in case question arise on procedure or materials for the work order.


• Benefits of Planning MaintenanceBenefits of Planning Maintenance– Long term plans insight– Decision making support– Optimizing connectivity among operation and

maintenance departments– Figuring out areas of cost reduction – Training areas and needs

Thank You