MINGGU VIII

LABORATORIUM SISTEM MANUFAKTUR

TEKNIK INDUSTRI ITS SURABAYA
2010
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Maintenance Strategy, CM v/s PM

1.

Corrective maintenance (CM)

The actions carried out (because of failure) to
repair component, equipment, or a system to a
stated condition
All actions performed as a result of failure, to
restore an item to a specified condition.

2.

Preventive Maintenance (PM)

All actions performed in an attempt to retain an
item in specified condition by providing systematic
inspection, detection, and prevention of incipient
failure
Scheduled maintenance : Preventive maintenance
performed at prescribed points in the items life
Which one will be held ???

Maintenance Strategy, stat v/s condt based

1.

Statistical based / reliability based

The components must be replace/repair at the
certain age
Objective : minimize total cost, fixed statistically
optimal PM interval

2.

Condition based / censored based

Feedback censor information used to perform
maintenance planning decision
Which one will be held ???

Condition Based Maintenance

(CBM)
= Condition Monitoring
= Predictive Maintenance
(PdM)

Based on known condition

Action / activity in maintenance

While for every strategy, we can choose action / activity
to maintain the system :
Repair, retaining or restoring the system to specified

condition. There are 3 types of repair : minimal

repair, perfect repair, imperfect repair
Replace, change failed item with the new one

DEFINITION
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Condition Based Maintenance

Maintenance based on the condition of an asset.
4 Asset: An item of value.
4 Condition: The state of an item.
is the art of monitoring your equipments health by taking simple
measurements of the machines performance.

Much the same way a Doctor will check (measure) your health by
checking your pulse, temperature, blood pressure etc

4 If these measures are abnormal the doctor may suggest

that they continue to take measurements but maybe

more often.
4 Or based on the first set of readings he may
recommend some process changes such as, better diet,
more rest etc.
4 He bases his decisions on known values or a standard,
on scientific research, or experience from training.
4 Thankfully the medical profession has a good
understanding of what is normal and what is not.
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Condition Monitoring :
The non-invasive monitoring of systems to obtain
knowledge of their condition; to distinguish wear,
impending failure or other deterioration without
disrupting the normal operation of those systems
Condition Based Maintenance
Maintenance requirements based on the
performance or physical state of the system
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Predictive Maintenance
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.
Schedule maintenance activities when mechanical or
operational conditions warrant to repair or replace
deteriorated equipment before obvious problems occur.
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Predictive Maintenance
4 Maintenance action based on actual condition

(objective evidence of need) obtained from in-site,

non-invasive tests, operating, and condition
measurements.
4 kegiatan perawatan yang berhubungan dengan

memonitor kondisi program perawatan preventif

dimana metode memonitor secara langsung
digunakan untuk menentukan kondisi peralatan
secara teliti (Blanchard, 1980)
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Predictive Maintenance
PdM adalah pemeliharaan berdasarkan penilaian atau analisa kondisi

(Condition Base) komponen atau peralatan

Kondisi itu harus dapat terukur (parameter terukur) seperti temperatur,
tekanan, vibrasi, tingkat keausan, tingkat korosi (corrosion rate),
tingkat keretakan, sisa umur kekuatan logam, viskositas minyak
pelumas, konduktivitas air pendingin, daya mampu, efisiensi dan lain
sebagainya.
Parameter-parameter terukur ini secara periodik dimonitor. Apabila
ada parameter yang mengalami gejala memburuk, maka monitoring
harus lebih diintensifkan dan diprediksi kapan kerusakan
sesungguhnya akan terjadi.
Apabila suatu komponen peralatan atau peralatan tidak memberikan
parameter terukur, maka Predictifve Maintenanace tidak dapat
dilaksanakan.
(Prajitno, 2005)

Predictive Maintenance
Timeline to Failure
Stressor
Applied

Noticeable Performance Degradation

Failure

Preventive Maintenance Zone

Predictive Maintenance Zone
48 Months
Additional 8% - 12% savings over a good preventive maintenance program

Degradation Zone

FAILURE

Preventive Maintenance Zone

Stressor
Applied

Predictive Maintenance Zone

No Failure

Proactive Operations and Maintenance Zone

Prediction
and Planning

Mitigation
and Repair

Fix What
Broke

Predictive Maintenance
Ada yang memandang

PdM dimasukkan dalam

PM karena keduanya
saling berkaitan
Namun ada yang melihat
PM dan PdM sebagai
dua hal yang berbeda
PdM tidak
menghilangkan PM.
Interval waktu antar
pemeliharaan
diperpanjang (sesuai
prediksi kondisi
peralatan)
dan volume pekerjaan
pada setiap
pemeliharaan bisa
terukur (efektif) sesuai
kebutuhan

Advantages and Disadvantage

Advantage
4 Increased component operational life/availability
4 Allows for preemptive corrective actions
4 Decrease in equipment or process downtime
4 Decrease in costs for parts and labor
4 Better product quality
4 Improved worker and environmental safety
4 Improved worker morale
4 Energy Savings
4 Field study showed a 8-12% savings over preventive
maintenance programs
Disadvantage
4 Increased investment in diagnostic equipment
4 Increased investment in training of staff
4 Savings potentials not readily seen by management

Barriers to adoption
Lack of management commitment
Failure to change traditional maintenance practices

Concern about acceptance by OEMs, insurance

and class
Technical complexity
Lack of independent advise
Overworked crew

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Key elements for successful implementation

1. Clear maintenance policy
Maintenance plans will be developed using best available techniques,
appropriate to the equipment's HSE and performance criticality.
A risk-based approach to extent and timing of maintenance activities
will be used. For rotating equipment , condition monitoring techniques
will be applied with a view to optimising equipment availability and
eliminating cause of failures"

2. Criticality analysis
Focuses attention on equipment items (or systems), failure of which will
significantly affect safety, health, the environment, or business
performance
Considers
4 Likelihood of failure
4 Consequence of failure
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3. Select appropriate maintenance task reactive,

planned, oncondition
Run-to-failure
A decision, based on a systematic analysis, not to undertake preventive
maintenance
E.g.- allowing a domestic fresh water pump to operate until it either
ceases to pump
Scheduled maintenance
Maintenance carried out in accordance with an established time schedule
E.g. overhaul fuel valves and replace nozzles every 8000 hours
Condition-based maintenance
Maintenance carried out according to the need indicated by condition
monitoring
E.g.- overhaul inert gas fan when vibration readings exceed limiting
values
Re-design
A decision, based on a systematic analysis, to reduce the probability of
failure by modification of the item
E.g.- re-design of a radar mast to reduce vibration-induced failures of a19
radar antenna

4. For on-condition tasks, choose appropriate

techniques, measurement intervals and limits.

Identify failure modes

Identify physical characteristics associated with each failure mode
Determine a non-intrusive method of measuring each physical
characteristic
Set limiting values

5. Establish training programme

6. Measure performance of cm programme

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Tahapan PdM
Setup
Monitoring

Repair
Inspection
schedule

Mengidentifikasikan peralatan dan prioritas item

berdasar dampak kerusakan
Menentukan bagaimana peralatan akan rusak
menggunakan pengetahuan operator dan sejarah
perawatan
Menyusun jadwal inspeksi
Mengumpulkan informasi peralatan
Uji peralatan yang sesuai dan memasukkan data dalam
database PdM
Menganalisa dan memonitor pengukuran
Menyelidiki adanya kerusakan, jika perlu dilakukan
perbaikan
Menentukan panjang waktu sebelum kegagalan terjadi

Perbaikan jadwal terjadi kerusakan

Menggunakan leadtime dengan baik

P-F INTERVAL
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example
4 Cracks in (railway) rails
4 Frequency of initiated cracks depends on traffic load, rail

4
4
4
4

material, rail geometry, particles on the rails, shocks from

trains with non-circular wheels, and so on
Inspection by a special rail-car with ultrasonic inspection
equipment (implies high cost)
Detection probability depends on the depth of the crack
PF interval is the time interval from the crack is observable
until a critical failure occurs
A critical failure may involve derailment and fatalities (i.e.,
CC difficult to assess)
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CONDITION MONITORING
TECHNIQUE
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Human Sense
sight, touch, smell,
hearing, (taste)

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Fluid Analysis
lubricants,
greases,
hydraulic oil

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4 Process parameter

analysis
temperatures,
pressures
4 Vibration and
acoustics
vibration analysis,
shock pulse,
acoustic emission
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thermography
Termal imaging

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Thickness
measurement
steel structure

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PERBEDAAN TIME BASE & CONDITION BASE

MAINTENANCE

EXAMPLE
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Obyek Pengamatan PdM

1. Tribologi, kegiatan pemantauan kondisi minyak pelumas yang
melibatkan pengetahuan tentang gesekan (friction) dari permukaan yang
berinteraksi

2. Kualitas siklus air, pemantauan dan analisa sifat-sifat kimia air

untuk mengetahui dampak kerusakan terhadap logam yang dilaluinya

3. Vibrasi, kegiatan Pemantauan dan Analisa sifat sifat getaran peralatan,

untuk mencari penyebab-penyebab getaran yang tidak normal.

4. Termografi, pemantauan distribusi termal pada suatu permukaan

dengan menggunakan radiasi infra merah, untuk mencari lokasi sumber panas
yang tidak normal.

5. Life assessment, kegiatan pemeriksaan, pengujian dan analisa

penyebab kerusakan terhadap bagian-bagian komponen (logam) peralatan
yang kritis

Teknologi yang digunakan

Nondestructive testing :
1. Inframerah analysis, untuk memonitor kegagalan
mekanik dan/atau kegagalan elektrik.

2. Vibration Analysis, paling produktif pada putaran

peralatan berkecepatan tinggi dan pada part yang paling mahal

3. Oil analysis, lebih bersifat prediksi

4. Acoustical Analysis, dilakukan pada suatu tingkatan
sonik hanya untuk peralatan mekanik. Sedangkan
teknologi ultrasonik lebih fleksibel dan reliabel untuk
mendeteksi permasalahan mekanik dan elektrik.

If you were measuring the current draw and the outlet flow
of a pump and could see that the draw was increasing yet the
outlet flow was decreasing, as compared to the
measurements you had taken over the previous months, you
would be right in assuming that the condition was
deteriorating and that some maintenance was due for the
pump, assuming of course that all the other variables had
stayed the same such as the material the pump was pumping
was the same etc. Flow and current cannot be measured on
all the machines so you have to choose a measurement
parameter that is more suitable for the majority of your
equipment. Which technology you use will depend on the
equipment you have. However vibration measurement is the
most versatile and gives the most information which is why
it is the most used measurement parameter.
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Equipment yang biasanya di PdM

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Example of degradation

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Regression Analysis

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Regression Analysis

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Regression Analysis

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Regression Analysis

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Oil condition

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Wind turbine oil test

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Automotive : Coolant and new oil

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Gearbox : water in oil

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Continuous Condition Monitoring

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communication

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