MAINTENACE STRATEGIES

Priyanka Mishra
WHAT IS MAINTENANCE STRATEGY?

Maintenance Strategy is a long-term plan,

covering all aspects of maintenance
management which sets the direction, and
contains firm action plans for achieving a
desired future state for the maintenance
function.

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WHY MAITENANCE STRATEGY IS REQUIRED?
For Time-based or performance-based
maintenance plans in any organisation, we can
implement strategy-based maintenance. By
using maintenance strategy we can-

1.Reduce maintenance plan creation time

2.Update scheduling information easily.

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 Maintenance Strategy

Unplanned
Planned
(Failure based)

Zero Hour
Predictive Reliability
Maintenance Preventive Corrective Breakdown
Maintenance Centered
(annual Maintenance Maintenance Maintenance
Maintenance
shutdown)

Condition Based Time based

Maintenance Maintenance

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Corrective Maintenance
Corrective Maintenance refers to
action only taken when a system or
component failure has occurred .It
is thus a retro-active strategy. It is of
minor nature.

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Breakdown Maintenance
Breakdown maintenance involves the repair
or replacement of equipment and
components after they have failed.

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Preventive Maintenance
In Preventive Maintenance, equipment is
repaired and serviced before failure occur. The
frequency of maintenance activities is pre-
determined by schedules. Preventive
maintenance aims to eliminate unnecessary
inspection and maintenance tasks, to implement
additional maintenance tasks when and where
needed and to focus efforts on the most critical
items.
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A)Time Based Maintenance(TBM)
For time-based maintenance planning, maintenance is
performed at specific intervals, for example, every two
months or every six months.
B)Conditional Based Maintenance(CBM)
Direction of maintenance actions based on indications of
equipment health as determined from non-invasive
measurement of operation and condition
indicators. CBM allows preventative and corrective
actions to be optimized by avoiding traditional calendar
or run based maintenance.

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Predictive Maintenance
Predictive maintenance refers to maintenance
based on the actual condition of a component.
Maintenance is not performed according to fixed
preventive schedules but rather when a certain
change in characteristics are noted.
Corrosion/erosion sensor supplying diagnostic
information on the condition of a system or
component play an important role in this
maintenance strategy.

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Zero hour Maintenance(Overhauling)
The set of tasks whose goal is to review the equipment
at scheduled intervals before appearing any failure,
either when the reliability of the equipment has
decreased considerably so it is risky to make forecasts of
production capacity . This review is based on leaving the
equipment to zero hours of operation. These reviews will
replace or repair all items subject to wear. The aim is to
ensure, with high probability, a good working time fixed
in advance.

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Reliability Centered Maintenance(RCM)

RCM involves the establishment or improvement

of a maintenance program in the most cost
effective and technically feasible manner. It
utilizes a systematic, structured approach that is
based on the consequences of failure. As such it
represents a shift away from time-based
maintenance tasks and emphasizes the functional
importance of the system components and their
failure/maintenance history.
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How to implement
Maintenance
Strategies

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 Identify the
Equipment's on
the basis of
criticality

Critical Equipment
Semi Critical(which
(which affects the Not Critical(which do
partially affects the
production and do not affect the
production but have
not have its stand production directly)
its stand by)
by)

Rapid Failure Mode

Failure Mode and and effects analysis
General analysis by
effects analysis (FEMA) of the
equipment type or
(FEMA) of the critical equipment's by
activity
equipment's reviewing most
significant failures

Define type of Define type of Define type of

Maintenance Maintenance Maintenance
strategy required for strategy required for strategy required for
the equipment the equipment the equipment

Define the Define the Define the

Maintenance Maintenance Maintenance
frequency frequency frequency
equipment wise equipment wise equipment wise

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How to determine Maintenance frequency
Equipment Type

Work order history and

knowledge

By calculating Mean time

between failure(MTBF)

Manufacturer’s
recommendation

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Preventive Maintenance Activity Flowchart
Trial Out of the equipment
will be done by operation in
Identify the major Return the PTW after PM
the presence of maintenance
equipment's whose PM is to and housekeeping of the
to ensure the work,
be done area
otherwise reissue of the
PTW .

If Equipment is released and Then record the PM data in

Prepare the work instruction
PTW issued then carry out SAP for future reference and
/SOP for the equipment and
the PM otherwise database.
resource planning
reschedule the PM .

Analysis of data and

Scheduling and Release of Request to Operation planning for improvement
Maintenance schedule by department for release of and incorporate changes in
Maintenance Department. equipment for PM. work instruction and SOP’s if
required.

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Zero Hour Maintenance( Annual Shutdown)
Activity Flowchart
If the equipment
Planning for annual Return the PTW and trial
performance is satisfactory
shutdown on the basis of run of equipment by
then job is complete
defect reporting and operation in presence of
otherwise reissue the PTW
database. maintenance
and carry our the job

Request for release of After completion of job

Housekeeping of area after
equipment to operation and Recording of data in SAP for
completion of job.
take PTW history and reference.

Analysis of the data and

Preparation related to safety
and environment
planning for improvement
Opening, inspecion and and incorporate changes in
rectification of problem SOP’s if required and spares
planning as per the
requirement.

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Breakdown Maintenance Activity flow chart
Return PTW and trial
Receipt of defects If equipment
run of equipment by
through defect performance is OK else
operation in presence
reporting or on phone. reissue of PTW.
of maintenance

Carryout inspection, Recording of data in

Identify if the defect is rectification of defect SAP. Analysis of data
chronic or Sporadic? and housekeeping of and planning for
area. improvement

If yes then Take PTW

Incorporate changes in
If the defect can be with proper isolation
work instruction and
rectified online or not else plan for outage of
SOP’s.
the equipment.

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Results For Measurement and controls of
Maintenance Strategy
 Repair and Maintenance cost per unit.
 Breakdown % of the equipment.
 Number of rework on the equipment.
 Availability of the equipment.
 MTTR(Mean Time To Repair)
 MTBF(Mean Time Between Failure)

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Thank You………..