Compiled By:

Rudolf Schenker
Pr.Tech.Eng., Reg.Eng.Tech
MTECH.- Mech. Engineering

© All Rights Reserved 2003

Development of Maintenance

European Maintenance Std.

International
Benchmarking
Maintenance
Maintenance Models
Standards
- CCFI

- Integration Model

- TPM

- RCM

Methods toOptimization

- Implementation
Compiled By:
Rudolf Schenker
Pr.Tech.Eng., Reg.Eng.Tech
MTECH.- Mech. Engineering
Maintenance: according to EN 13 306:2001
© All Rights Reserved 2003

Development of Maintenance

European Maintenance Std. Maintenance

Maintenance
Before a
detected fault
Benchmarking

Maintenance Models Preventive Corrective

- CCFI
Maintenance Maintenance

- Integration Model Forced/Unplanned

Deferred or Immediate
- TPM
Condition Based Predictive
- RCM Maintenance Maintenance
After a
Methods toOptimization detected fault
Scheduled/Planned (cycle),
continuous or per Order

- Implementation
Compiled By:
Rudolf Schenker
Pr.Tech.Eng., Reg.Eng.Tech

Maintenance Types
MTECH.- Mech. Engineering

© All Rights Reserved 2003

Development of Maintenance Corrective Maintenance

immediate Diagnose the E-Equipment
European Maintenance Std.reporting, (Loose Connection...)

transparent throughout the Organization of all

find,
control

Support using all Material & Equipment

help Diagnose the Process
Benchmarking (Limit switch not made...)

(Audio, Video - wireless, web)

Maintenance Processes
Maintenance Models
Preventive Maintenance

All work stations

- CCFI
planned Inspection order (Report to Operator or
Inspection,
- Integration Model
Reliable Maintenance/Inspection Center)
and correct Support during Inspection execution
- TPM (Guidance, Photos, Documentantion)
execution
- RCM
Predictive Maintenance
Methods toOptimization
Monitoring the E-Equipment
j.i.t. (Wear/Life expectancy....)
and
- Implementation factual Monitoring the Mechanics (Bearings,
warnings
Gearboxes, Blowers, Compressors...)
Compiled By:
Rudolf Schenker
Pr.Tech.Eng., Reg.Eng.Tech

Maintenance Types and its Results

MTECH.- Mech. Engineering

© All Rights Reserved 2003

Development of Maintenance Corrective Maintenance

immediate Reacted too late, i.e. if a Error occurred
European Maintenance Std.reporting,

Transparency throughout the Organization of all

e.g. Breakage, Leakage, Breakdown
find,
control
help Extreme high Resulting Costs
Benchmarking

Maintenance Processes
Maintenance Models
Preventive Maintenance

Using a CMMS.
- CCFI
planned Time and/or Life Cycle driven
Inspection,
- Integration Model
Reliable (km, work hours, poor Quality)
and correct
- TPM Maintenance too often / thus too expensive
execution
- RCM
Predictive Maintenance
Methods toOptimization
Just-in-Time-Maintenance
j.i.t. Indicators, CBM
and
- Implementation factual Optimal Maintenance Timing ,
warnings planned inline
with the Production !
Compiled By:
Rudolf Schenker
Pr.Tech.Eng., Reg.Eng.Tech

Experiences: Distribution of the Strategic Measures

MTECH.- Mech. Engineering

© All Rights Reserved 2003

Development of Maintenance
If effective Maintenance Strategies are to be implemented,
then the distribution of Maintenance Techniques should be
European Maintenance Std. according to the following guidelines:

Benchmarking 33 % of the damage caused; to be detective

Maintenance Models
countered by CBM. (detective
maintenance)
- CCFI
25% of the damage caused; to combat predictive
- Integration Model with Predictive Maintenance
5% of the damage caused; to be avoided preventive
- TPM
with Preventive Maintenance
- RCM 33% of the damage caused due to “run
to failure” run to failure
Methods toOptimization
4% of the damage caused due to Design
redesign
- Implementation
Compiled By:
Rudolf Schenker
Pr.Tech.Eng., Reg.Eng.Tech

Time Concepts: Equipment Availability vs. Demand

MTECH.- Mech. Engineering

© All Rights Reserved 2003

Development of Maintenance

European Maintenance Std.

Down State Up State

Benchmarking

External
Maintenance Models Standby Operating
Idle State Disable
State State
State
- CCFI

- Integration Model

- TPM
Required Non Required Required Non Required
- RCM Time Time Time Time

Methods toOptimization

- Implementation
Compiled By:
Rudolf Schenker
Pr.Tech.Eng., Reg.Eng.Tech

Time Intervals: according to EN 13 306:2001

MTECH.- Mech. Engineering

© All Rights Reserved 2003

Development of Maintenance

European Maintenance Std.

Failure Time Between Failure (TBF) Failure

Downtime
Benchmarking Up Time (UT)
(DT)

Maintenance Models Operating

Corrective Preventive External
Idle Standby Time
Maintenance Maintenance Disable
- CCFI Time Time Time Time Between
Time
(CMT) (PMT) (IT) (SBT) Failure
(EDT)
- Integration Model (OTBF)

- TPM MFT MTTR MTTM MTTF

- RCM MTBR
MTBF
Methods toOptimization

- Implementation
Compiled By:
Rudolf Schenker
Pr.Tech.Eng., Reg.Eng.Tech

Time Concepts: according to DIN 8743

MTECH.- Mech. Engineering

© All Rights Reserved 2003

Development of Maintenance
Effective Working Downtime due Downtime due Inspection Feed Ancillary
Time to Machine to other Time Time Time
European Maintenance Std.
Effective Working Time

Overall Working Time

Benchmarking Operating Time

Machine Operating Time

Maintenance Models

- CCFI
Effective Working Time Total Working time which the packaging machine is operating without breakdown.

- Integration Model Machine dependant Total time during which the packaging machine is stopped due to faults caused by the
downtime machine itself.

- TPM Machine in-dependant Total time during which the packaging machine is stopped due to faults caused by other
downtime reasons that the machine itself.
- RCM Inspection Time Time required for inspection and measurements.

Total time where the machine is at standstill due to set-up, format change-over, servicing
Methods toOptimization Ancillary Time
and cleaning, starting and stopping

Operating Input Number of Blisters or Package output during operating time.

- Implementation Effective Output Number of Blisters or Package output during overall working time.

Efficiency Ratio Ratio of effective output to set output (actual output/set output)
Compiled By:
Rudolf Schenker
Pr.Tech.Eng., Reg.Eng.Tech

Relationships: according to VDI 2246

MTECH.- Mech. Engineering

© All Rights Reserved 2003

Redundant Reliability
improvements, e.g.
complex
Development of Maintenance
Automation/Controls
could complicate the
Maintenance Maintainability.
European Maintenance Std.
Effort
(Maintainability)
will be high if Maintainability
Benchmarking Reliability is low.
Improve
Maintenance Models Maintainability
and/or
- CCFI Reliability to
improve
- Integration Model Availability.

- TPM
Production Equipment
- RCM
Profitability,
Methods toOptimization
Environmental,
Health & Safety

- Implementation
Reliability Availability
Compiled By:
Rudolf Schenker
Pr.Tech.Eng., Reg.Eng.Tech

Definitions: as per EN 13 306

MTECH.- Mech. Engineering

© All Rights Reserved 2003

Development of Maintenance
Reliability:
European Maintenance Std.
 Ability of an item to perform a required function under given
conditions for a given time interval. (rs note: reliability is high (1) when the
probability of failure is low))

Benchmarking

Maintenance Models Maintainability:

 Ability of an item under given conditions of use, to be retained
- CCFI
in, or restored to, a state in which it can perform a required
- Integration Model function, when maintenance is performed under given
conditions and using stated procedures and resources. (rs:
- TPM maintainability is high (1) when maintenance/effort is high (1)

- RCM
Availability:
Methods toOptimization  Ability of an item to be in a state to perform a required function
under given conditions at a given instant of time or during a
- Implementation
given time interval, assuming that the required external
resources are provided. (rs: Availability is high (1) when equip. is always available
for production)
Compiled By:
Rudolf Schenker
Pr.Tech.Eng., Reg.Eng.Tech

Wear Definitions: according to DIN 50 320

MTECH.- Mech. Engineering

© All Rights Reserved 2003

Development of Maintenance

European Maintenance Std.

Benchmarking

Maintenance Models

- CCFI

- Integration Model

- TPM

- RCM

Methods toOptimization

- Implementation
DIN 31 051: Wear Allowance
…considering maintenance, wear is allowed to a state where the
functional performance, based on defined operational conditions, is not
affected.
Compiled By:
Rudolf Schenker
Pr.Tech.Eng., Reg.Eng.Tech

Summary: International Maintenance Standards

MTECH.- Mech. Engineering

© All Rights Reserved 2003

Development of Maintenance
DIN 31 051 Maintenance Definitions
DIN
European Maintenance Std. 13 306 Maintenance Terms and Explanations

DIN 8743 Time Concepts

Benchmarking
SAE - JA1011 Evaluation Criteria for RCM Processes .
Maintenance Models A Guide to the Reliability-Centered
SAE - JA1012
- CCFI
Maintenance (RCM) Standard
VDI 2886 Benchmarking Design
- Integration Model
Relationships of Maintainability, Availability,
- TPM VDI 2264
Reliability
- RCM DIN 50 320 Maintenance; Wear Definitions
Methods toOptimization EN DIN 32 736 Building Management - Work Areas
VDMA 24 196 Commercial Business Management
- Implementation DIN ISO 10011 Quality Audit Techniques
Compiled By:
Rudolf Schenker
Pr.Tech.Eng., Reg.Eng.Tech
MTECH.- Mech. Engineering

© All Rights Reserved 2003

Development of Maintenance

European Maintenance Std.

Benchmarking

Maintenance Models

- CCFI

- Integration Model

- TPM

- RCM

Methods toOptimization

- Implementation