Introduction to

Maintenance
Management
Khusnun Widiyati, Ph.D
Department of Mechanical Engineering
Faculty of Industrial Technology
Universitas Pertamina
 Interpret different
types of maintenance
Class
management
Objective
Describe level of
maintenance
 Performance of an equipment depend
on design, operating environment,
usage intensity, maintenance activity

Degradation and failure mechanism

Previously.... vary from object to object

Maintenance activities is required to

control degradation and/or restore
performance
 • Inspection→check for conformity by measuring,
observing, testing, or gauging the relevant
characteristics of an item. Inspection can be
carried out before, during or after other
maintenance activities.
• Compliance test→ to show whether or not a
characteristic or a property of the item complies
with the states specification
Maintenance actions • Monitoring→ performed manually or
automatically which is intended to observe the
actual state of the item.
• Is used to evaluate any changes in some
parameters of the equipment with time
• Monitoring can be continuous, over
interval of time, or after a given number of
operations
 • Routine maintenance→regular or repeated
elementary maintenance activities
• Routine maintenance includes
cleaning, tightening of connections,
checking liquid level, lubrication, etc.
• Overhaul→ a comprehensive set of
examination and actions carried out in
Maintenance Actions order to maintain the required level of
availability and safety of the equipment.
(cont.)
• Rebuilding→action following the
dismantling of the item and the repair or
replacement of those components that are
approaching the end of their useful lives
and/or should replace regularly.
 • Improvement→combination of all technical,
administrative and managerial actions intended
to ameliorate the dependability of the item
withoput changing its required function
Rebuilding • Modification→combination of all technical,
administrative and managerial actions intended
includes: to change the required function of the item
• Repair→ physical action to restore the required
function of faulty equipment.
 • Fault diagnosis→actions taken for fault
recognition, fault localization, and fault
isolation at the apropriate indenture
level and cause identification
• Fault correction→action taken after
diagnosis to put the item into a state in
Actions during Repair which it can perform a required
function
• Function check-out→action taken after
maintenance actions to verify that the
item is able to perform the required
function
 • Turnaround (TA)→ planned, periodic
shutdown (total or partial) of a plant
(refinery, chemical plant, power plant,
etc) to perform overhoul and repair
activities and to inspect, test and
Maintenance Action replace process material
(cont.) • Expensive due to lost of production
(duration of several weeks) and
direct costs for labor, tools, heavy
equipment and material to execute
the project
 Plant level: periodic shutdown for major
maintenance activities

Intermediate level (module, subassembly,

Carrying out
maintenance
etc): standard replacement (electronic card,
electrical motor, etc).
Component level (PM action to replace
filters, lamps, belts, etc based on age/or
usage).
Maintenance
Management
• Decision making made related to
maintenance in order to formulate
strategy, technical, operasional level, and
implement the decition into action.
Classification of Maintenance Actions
Preventive Maintenance
 Require taking Increase the
an operational span of its
item out of lifetime and/or
service reliability
Preventive
maintenance
(PM) actions Actions: visual
inspecyion,
Carried out in lubrication,
descrete time testing, planned
replacement of
parts
 Detect the onset
Prevent failure
of failiure
Aims of PM
Actions Find hidden
failure: to check if
a failure has
occured
Effect of PM Action
 Condition based
maintenance

• Measureable parameter
that correlates with the
degradation over time and
the onset failure
• Changes in the measurable
parameter are obtained
from data collected usin
condition-monitoring
techniques
 Actions are carried out at convenient
moments which are unpredictable.

• Internal to the object

Opportunistic • Failure of a component providing an
opportunity to carry out PM action on some
maintenance of the non-failed component
• External to the object
• Object in the idle state due to external factors
(temporary shutdown due to excess inventory)
provide opportunity to carry PM
 • Reliability performace measures
• Interval reliability: probability of no failure over
Measure of a specified interval
Engineered • Interval availability: the fraction of the time in
which the product/system is in the operational
Objects (non-failed) state over a specified interval
• The number of failure over a specified interval
Measure of
Engineered
Objects

• Non reliability performace measure

• Technical, operational, economical, environmental impact, etc
Decomposition
of Engineered
Project
A product can be berakdown into
its multilevel constructing
elements
Maintenance Cost
Maintenance • Direct costs • Indirect costs
• Costs due to • Costs resulting from
Costs maintenance and the consequences
associated with failure
repair actions or unplanned
• E.g.: Labor cost, maintenance actions
material cost, spare • E.g.: loss due to
part cost, contractor production stops
costs, etc. because of
maintenance and
repair, cost of
accident, insurance,
etc
Degradation of performace
• Desired performace → starting point for designing and
building/manufacturing
• Performace depends on the usage and operating environment
• Thus, carefully selecting components and materials to ensure desired
performance
Performace degrade of
object

degradation of
degradation of material
components of object
Maintenance
from
Business
Perspective
 Characterization of Degradation

Multi State
Two-State Characterization
Characterization (Finite Number of
States)
 • X(t)=1 corresponding to the
object being in the working
state (performace
satisfactory or acceptable)
• X(t)=0 corresponding to the
object being in the failed
state (performance is
unsatisfactory or
unacceptable)

Two-State Characterization
 • X(t) is assumed values form the
set 1,2, … , 𝐾
• X(t)=i, 1<i<K, corresponding to the
object being in partially
acceptable in the working state
(high value i implies higher level of
degradation)
• X(t)=K, corresponding to the
obaject being unacceptable/failed
• 𝑇 = 𝑖𝑛𝑓 𝑡: 𝑋 𝑡 = 𝐾

Multi State Characterization

(Finite Number of States)
Maintenance Action
• Control/ prevent the deterioration process leading to failure of an
engineered object (Preventive maintenance/PM)
• Restore the object to its operational state through corrective action
after a failure (corrective maintenance/CM)
 Preventive
Maintenance
VS
Corrective
Maintenance
 After attending the class, what can you
inferred from maintenance? And, what are
the consequences of equipment failure? Give
examples.

Discuss in pair Explain the following statement:”building

with your reliability is costly, however not having
adequate reliability is costlier”
friend
What is the effect of PM effort level on CM
and PM cost, and what are the implication?