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ภาคผนวก PM Optimization
ภาคผนวก PM Optimization
Optimization
How to Review
Existing Maintenance Program?
Maintenance Program
Apply PMO
Failure modes
2
PM Optimization Steps
STEP 1 - TASK COMPILATION
STEP 2 - FAILURE MODE ANALYSIS
STEP 3 - RATIONALISATION AND FAILURE MODE REVIEW
STEP 4 - FUNCTIONAL ANALYSIS
STEP 5 - CONSEQUENCE EVALUATION
STEP 6 - MAINTENANCE POLICY DETERMINATION
STEP 7 - GROUPING AND REVIEW
STEP 8 - APPROVAL AND IMPLEMENTATION
STEP 9 - LIVING PROGRAM
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PM Optimization
STEP 1 - TASK COMPILATION (for New Plant)
Operator Lubrication
Rounds. Rounds.
Sources of Preventive Maintenance
Contractor Standard
Schedules. Vendor Operating
Maintenance Procedures
Manuals.
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PM Optimization
Existing
STEP 1- TASK COMPILATION Maintenance Program
PM Optimization
STEP 2 - FAILURE MODE ANALYSIS
Task Interval Trade Failure
PM Optimization
Each failure
STEP 4 - FUNCTIONAL ANALYSIS establish the
function lost
PM Optimization
STEP 6 - MAINTENANCE POLICY DETERMINATION
This step establishes new or revised maintenance policies. During this step the
following become evident:
RCM
Failure Mode Principle Maintenance Policy
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PM Optimization
EVIDENT FAILURE HIDDEN FAILURE
Is The Failure To The Operating
Yes ตรวจพบได้ ระหว่ าง Normal Operation NO
Crew During Normal Operations? HIDDEN-FAILURE
Does The failure Cause A Loss Of CONSEQUENCES
Function Or Secondary Damage
มีThat
ผลกระทบเรื $อง Safety
Could Have A Direct Adverse
NO Scheduled maintenance is required to
ensure the level of availability
Effect On Operating Safety?
Does The Failure Have A necessary to avoid exposure to a multiple
ส่ งผลกระทบโดยตรงกั บกําลัOnงการผลิต
Direct Adverse Effect failure.
YES
Operational Capability Detect ได้ ดCondition
Is There a Cost-Effective ้ วย
YES NO YES Monitoring Task To Detect
OPERATIONAL NON-OPERATIONAL Condition Monitoring
Potential Failure?
SAFETY CONSEQUENCES CONSEQUENCES (ECONOMIC) CONSEQUENCES (ECONOMIC) Condition
Mandatory PM performance is PM Performance is desirable if PM Performance is desirable Monitoring NO
required to reduce the risk of failure to cost is less than the total cost of if its cost of repair of Task
PM cost <operational
Production lostand+CM cost PMfailures
cost it<prevents.
CM cost Is There A Cost-Effective
an acceptable level. consequences those ลด Failure Rate ได้
YES Time Directed Task
repair of those failures it prevents. โดยใช้ TimeThe
To Reduce Based
FailureMaintenance
Rate?
IsDetect
There aได้ ด้วย
Cost-Effective IsDetect ได้ ด้วย
There a Cost-Effective Detect
Is There ได้ ด้วย
a Cost-Effective Time
NO
Condition Monitoring Task To Condition Monitoring Task To YES Condition Monitoring Task To Directed
Condition Monitoring YES Condition Monitoring Condition Monitoring
Detect Potential Failure? Detect Potential Failure? Detect Potential Failure? Task
ลด Failure
Is There Rate ได้
A Cost-Effective
NO
Condition
NO
Condition
Monitoring NO
YES โดยทํFailure
า Failure
FindingFinding
Task Task
Monitoring
Task Task
Failure
(Function
To Reduce The FailureTest)
Rate?
ลดIsFailure
There A Cost-Effective
Rate ได้ ลดIs There A Cost-Effective
Failure Rate ได้ Is There A Cost-Effective
ลด Failure Rate ได้ Finding NO
Time Directed Task Time Directed Task YES Time Directed Task Task
โดยใช้ Time BasedTheMaintenance YES โดยใช้ To
Time Based Maintenance โดยใช้ToTime
ReduceBased Maintenance Can The Failure
To Reduce Failure Rate? Reduce The Failure Rate? The Failure Rate?
YES ยอมรับ Failure ทีเ$ กิดขึนB ได้ หรือไม่
Be Tolerated
Time
NO NO Monitoring NO
Time NO
Task
Redesign Monitoring Run To Run To Run To
Task Redesign
Required Failure Failure Failure
Required
IMPACT IMMEDIATE IMPACT DELAYED 12
PM Optimization
STEP 6 - MAINTENANCE POLICY DETERMINATION คุ.มหรือไม5ที่จะทํา
• The elements of the documented maintenance program that are cost effective,
and those that are not (and need to be eliminated),
Change to CBM
• What tasks would be more effective and less costly if they were condition
based rather than overhaul based, ไม5รู.ว5าทําไปทําไม
•What tasks serve no purpose and need to be removed from the program,
Extend Interval
•What tasks would be more effective if they were done at different frequencies,
ใช. new technology
PM Optimization
STEP 7 - GROUPING AND REVIEW
establishes the most efficient and effective method for managing the
maintenance of the asset given local production factors and other
constraints.
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