Presentation title: Maintenance Management & Planning Strategies

Speaker name: Adel Al-Onaizi

Job title: Senior Electrical Engineer Maintenance
Company: Kuwait Oil Company

AGENDA
About Maintenance
Maintenance Management
Maintenance Strategies
Risk Based Approach & Inspection
Effective Planning Strategies

Maintenance:- A means to maintain and improve the quality of

the elements involved in a production process, continuously and
cost-effectively through detecting and controlling the deviation.
Maintenance Challenges:
To Deliver :

Regulatory Compliance
High Plant availability
Reliable Equipment
Cost Effective & Target Maintenance
Statuary/HSE Compliance

Delivery Sustainable Improvement

is hard!
Little time available
Resources reducing
Priories changing

Source of Unreliability

Operations
30 50 %

Assets
30 40 %

Maintenance
10 30 %

Poorly defined & operating

procedures & Training
Ineffective cross functional
team-working
Lack of measures/targets
Inconsistent Operation
Lack of training
Inaccurate initial specification
Poor design for maintenance or
operation
Change of use/modification
Ageing asset
No adequate strategy
Inadequate
monitoring/knowledge of
condition
Poor/no rebuild specifications
Lack of technical skills/training

Unreliable
Plant

Key steps to successful

6
IMPROVEMENT

2
INSPECTION

5
EXECUTION

Management
1

3
4
SCHEDULING

PLANNING

Implementing Maintenance
1.Establish business requirements
2. Carry out equipment audit
3. Carry out reliability & criticality audit
4. Select appropriate maintenance strategy/task
5. Plan work, issue work & carry out work
6. Record results & determine any further maintenance action
7. Review & measure effectiveness
Overview of typical Maintenance Implementation Stages

IMPLEMENTATION PHASE
Setting up Maintenance Programme can be viewed in four phase,
viz.
Initial Set-up
Routine Maintenance
Obtaining useful KPIs
Optimization and Review

Selecting a Maintenance strategy

Selecting an appropriate strategy and choosing one or more
techniques became simpler when failure mode are understood. A
schematic of the decision process is shown in the figure below:
Overview
Detail
Comments
What are
Maintenance
Techniques?

Why do we
chose
particular
maintenance
techniques?

Tasks or procedures
designed to establish
serviceability
Match technique to
failure mode
and criticality
Select appropriate
maintenance strategy
Feasibility of application
of maintenance
technique

Detect/inspect
Repair/restore
Exchange/Re-design
Historic information
Failure mode analysis
(FMEA) (FMECA)
On failure
Time based (Cyclical)
On condition
Design out
Opportunity
Simplest technique
Safe to implement
Physically possible
Confidence in technique
Cost effective
Training requirements

Maintenance Decision Diagram

Is the rate of
deterioration or
time of failure
predictable &
consistent ?

Is there a
reliable
indication/early
warning of
failure ?

Is
Maintenance
likely to be
cost
effective ?

Is the interval
N
between
detection &
failure sufficient
to act on ?

Is the suitable condition

monitoring routine that
is cost effective &
implemented and
operate ?

Y
FIXED TIME
MAINTENANCE

CONDITION
BASED
MONITORING

Would
routine
service
extend file to
failure ?

Is Routine
Service cost
effective ?

OPERATE TO
FAILURE
OPERATE TO
FAILURE

Agreed
Maintenance
policy

Maintenance Strategy Decision

Planned Maintenance

Preventive Maintenance
Scheduled or Fix Time Maintenance (FTM)
- Time interval based
Condition Based or Predicative Maintenance
(CBM)- Equipment Condition Based
Routine Asset Care (RAS)
- Regular running maintenance e.g. servicing, adjustments,
level checks

Proactive/Predictive or Design Out Maintenance [DOM]

- Improvement based

Maintenance Strategy Decision

Unplanned Maintenance

Corrective Maintenance or Operate to Failure

- Reactive or Breakdown

Risk Based Approaches

Clear need to anticipate future problems
Identify future risk and opportunities
Increasing Number of Application:
Pressure System
Equipment Maintenance Strategies
Critical spares
Maintenance & Calibration routines
Critical trips and alarms
Validation

Risk Assessment Matrix

Consequence

Insignificant
1

Minor
2

Moderate
3

Major
4

Catastrophi
c
5

A (Rare)

B (Unlikely)

C (Moderate)

D (Likely)

E (Almost
Certain)

Likelihood

Legend and outcomes:

E extreme risk; immediate action required
H high risk; senior management attention needed
M moderate risk; management responsibility must be specified
L low risk; manage by routine procedures

RISK BASED INSPECTION (RBI)

Optimize Operations, Maintenance and Inspection Regime
Maximize Run Length of Facilities with Minimum of Risk leading
to improved facility availability
People

OPERATIONAL
RISK

Equipment

Production

RISK BASED INSPECTION

Target Approach

Criticality
Analysis/
Opportunity
Assessment

HIGH

Detailed
Assessment

Decision
Process
MEDIUM

LOW

Task
Definition

Rapid
Assessment
(80/20)
Analysis

Generic
Assessment

Document
Strategy

RISK BASED INSPECTION

Target Approach Screening

RISK BASED INSPECTION

Target Approach Critical Analysis

RISK BASED INSPECTION

Performance Improvement

RISK BASED INSPECTION

Document Maintenance Strategy

PLANNING MANPOWER PRODUCTIVITY

PLANNING MANPOWER PRODUCTIVITY

HOW TO PLAN MAINTENANCE WORK

HOW TO PLAN MAINTENANCE WORK

HOW TO PLAN MAINTENANCE WORK

THANK YOU.