Welcome to ATF205Introduction to Modern Maintenance

Practices

► Dr David Baglee► david.baglee@sunderland.ac.uk► Phone: 515 2869► http://osiris.sunderland.ac.uk/~cs0dba/

AMAP The Industry Centre Wessington Way

► Thursday 1pm-5pm (including project management)

► Lectures and lab. ► Two assignments

Maintenance and Asset Management Links

► http://www.skf.com/aptitudexchange/glossary.html► http://www.reliabilityweb.com► http://www.reliabilityweb.com/excerpts/► http://www.maintenanceresources.com► http://www.maintenanceworld.com► http://www.plant-maintenance.com► http://www.mt-online.com► http://www.cmmscity.com/articles/

cmms_articles.htm

Introduction to Maintenance

Dr David BagleeSchool of Computing and Technology

Maintenance Spending

► Europe €120 Billion Annual Spend Employs 2 million people

► United Kingdom £16 Billion Annual Spend Employs ?

No records indicate reactive maintenance spending

Trends

► Assets Assets must run longer Impact of asset failure can be very large

► Expertise Downsizing and aging workforce has caused ‘skill

gap’ at plant sites Technology is evolving faster than it can be adopted

► Working Practices Asset management is moving from reactive to

proactive Abnormal situation management procedures are

improving operations effectiveness

Recent Events

► Tube Crash - Chancery Lane, London Bolts holding motor failed, train derailed 30 hurt. £ms

lost

► Electricity Supply Failure - USA, Italy, UK► Rail Crash - Hatfield, UK

4 people died: lack of maintenance on lines

► Concorde Crash - CdG Airport, Paris► BP Refinery Explosion, Texas

Vent system not maintained $ms damage loss of life

► Food contamination at Cadburys: Unchecked pipe during maintenance leaked oil, 75’000

bars recalled

Example: Car Maintenance

►What must be done to maintain your car? Change the oil every 6,000 miles Check and/or change air filter Check and/or change hoses and belts Clean inside/wash outside Replace brake pads Regular inspection

Maintenance Strategies

► Run-to-fail► Time based► Condition Based

►Modern Maintenance Reliability Centred Maintenance (RCM) Total Productive Maintenance (TPM) Condition Based Maintenance (CBM)

Period between 1900-Present

Characteristics of equipment Maintenance philosophy

First generation maintenance

(1900-1939)

Equipment is simple and easy to repair

Basic and routine maintenanceReactive maintenance, “only repair when broke”

Second generation maintenance

(1945-1979)

Equipment is more complex, greater dependence of industry on equipment

Maintenance costs are higher in relation to other operating costs

Planned preventive maintenanceTime based approach

Total Productive Maintenance (TPM) ‘Total' employee participation.

Team based approach to maintenance, examines “culture and people” not systems

Third generation maintenance

(1980s-present)

Equipment complexity increasingAccelerated use of automationDowntime very expensiveIncreasing use of Just-In-Time

Customers now demanding higher

quality goods

Tightening legislation on safety

Condition monitoring (CM), hazard studies, failure modes and effect analysis

Reliability centred maintenance (RCM) examines “machine and systems”

Computer aided maintenance managementMulti-skilled workforceEmphasis on equipment reliability and

availabilityMaintenance is now proactive and strategic

Example: Car Maintenance

► Implications of poor car maintenance? Premature failures Increased running costs Unexpected breakdowns Personal injury or death Government shuts you down

Poor planning

Barriers to maintenance strategy development

► Limited staff► Lack of training► Inadequate diagnostic equipment►Missing technical documentation► Budget issues► Inadequate monitoring of equipment ► Lack of management commitment► Poor morale

Neglected Maintenance

►Operating equipment in manual override

► Incorrectly adjusted equipment► Inefficient operations► Inoperative equipment► Steam, air, water leaks► Faulty control systems

Results of Poor Practices

► Short and Long term effects: Increased energy costs Increased major maintenance work Increased capital costs due to shortened

equipment life Continued morale degradation HEALTH & SAFETY INNAPROPRIATE TASKS

Correct Strategy?

• Planned?

• Cost effective

• Safe

• Identify ‘why’

•Alternative task?

Costs Involved

► Equipment purchase► Training► Extra staff

► Costs can be insignificant when compared with cost of not improving maintenance methods

► Industry loses per year are huge due to inadequate maintenance activity

Benefits

► Improved equipment efficiency► Increased product quality► Identify equipment defects► Reduced equipment failures► Increased production► Improved safety► Minimize damage to equipment► Provide guidelines for new equipment purchase► Effectively prioritize decreasing resources► Improve staff morale

Recent Advances Equipment1.) PDA2.) Cost £2503.) Metal-on-mount ICode RFID Tags: 10p4.) USB Vibration Sensor £100

PDA Specification:WiFiBluetoothUSB HostCompact Flash Slot

Recent Advances

Thermal imagery, cost £300-£30K

Self Study

► Take time to examine the Glossary of Terms provided on the following web site: www.skf.com/aptitudexchange/glossary.html

► Next week: Risk in project management. Alan Stafford Design in maintenance. Dave Knapton