SoMMME

Department of Mechanical Engineering

EMG 2519 Maintenance Engineering and

Industrial Safety

Maintenance Planning

© Juni 18 MuD Universität Paderborn

James Kuria Kimotho
 SoMMME
Department of Mechanical Engineering

Content

Evolution of maintenance strategies

Basics of maintenance planning
Selection of optimal maintenance methods

© Juni 18 MuD Universität Paderborn

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 SoMMME
Department of Mechanical Engineering

Evolution of maintenance strategies

© Juni 18 MuD Universität Paderborn

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 SoMMME
Department of Mechanical Engineering

Maintenance strategies

Corrective maintenance
Preventive maintenance
Reliability centred maintenance (RCM)
Condition based maintenance (CBM)

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 SoMMME
Department of Mechanical Engineering

Maintenance Strategies
Corrective Maintenance
– A maintenance task performed to identify, isolate, and rectify a
fault so that the failed equipment, machine, or system can be
restored to an operational condition within the tolerances or limits
established for in-service operations

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 SoMMME
Department of Mechanical Engineering

Maintenance Strategies
Preventive Maintenance
– Refers to regular, routine maintenance to help keep equipment up
and running, preventing any unplanned downtime and expensive
costs from unanticipated equipment failure.

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 SoMMME
Department of Mechanical Engineering

Maintenance Strategies
Reliability Centred Maintenance (RCM)
– Is a corporate-level maintenance strategy that is implemented to
optimize the maintenance program of a company or facility
– Implementation of a specific maintenance strategy on each of the
assets of the facility
– Identification and prioritization of failure modes that can affect the
system function

RCM

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Corrective Preventive Condition-Based
maintenance maintenance Maintenance Redesign
(CM) (PM) (CBM)

Predictive
Real-time
Maintenance
monitoring
(PdM)
7
EMG 2519: Maintenance Engineering and Industrial Safety/12/06/2018
 SoMMME
Department of Mechanical Engineering

Maintenance Strategies
RCM logic tree

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 SoMMME
Department of Mechanical Engineering

Maintenance Strategies
Condition Based Maintenance (CBM)
– Condition monitoring through sensors/data acqusition
– Fault diagnostics – fault detection, isolation and identification
– Prognostics – estimating when the system is likely to fail
(estimating remaining useful lifetime (RUL))

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 SoMMME
Department of Mechanical Engineering

Maintenance Strategies
Elements of CBM - Maintenance
planning
System - Reliability control

Decision

1 2 3 4
Data Feature
Diagnosis Prognosis
Acquisition Extraction

2
3 4
0.2

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Vibr. Ampl. / g

X: 76.56
0.1
Y: 0.202 -3
10
2 2 Healthy bearing 1.5
0 Outer ring fault
0 100 200 1.5 Inner ring fault 1
Feature 2
Vibration / g

0
Frequency / Hz

HI
1
0.5
8000 RUL
t
-2 0.5 c
0 1 2 3 4 0
Inst. Freq / Hz

0 0.05 0.1
7000 0 2 4 6
Time / s Feature 1 4
10 Time / h
6000
0 2 4 6

Time / h

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 SoMMME
Department of Mechanical Engineering

Maintenance Planning

Purpose of maintenance planning

– Defect elimination
– Failure avoidance
– Risk elimination
– Equipment reliability
– Least operating costs
– Maximum production

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 SoMMME
Department of Mechanical Engineering

Maintenance Planning
Role of maintenance department
– Planning and repairing equipment/facilities to acceptable
standards
– Developing and implementing a regularly scheduled work
program for the purpose of maintaining satisfactory
equipment/facility operation as well as preventing major problems
– Preparing realistic budgets that detail maintenance personnel and
material needs
– Managing inventory to ensure that parts/materials necessary to
conduct maintenance tasks are readily available
– Keeping records on equipment, services, etc.

© Juni 18 MuD Universität Paderborn

– Developing effective approaches to monitor the activities of
maintenance staff
– Developing effective techniques for keeping operations personnel,
upper-level management, and other concerned groups aware of
maintenance activities

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 SoMMME
Department of Mechanical Engineering

Maintenance Planning

Role of maintenance department (Cont.)

– Training maintenance staff and other concerned individuals to
improve their skills and perform effectively
– Reviewing plans for new facilities, installation of new equipment,
etc.
– Implementing methods to improve workplace safety and
developing safety education-related programs for maintenance
staff
– Developing contract specifications and inspecting work performed
by contractors to ensure compliance with contractual

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requirements

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 SoMMME
Department of Mechanical Engineering

Basic Maintenance Management Process

• Procurement of parts, tools, and materials

• Coordination and delivery of parts, tools and
materials Employs methods such as:
• Identification of methods and sequencing • Program evaluation and
• Coordination with other departments review technique (PERT)
• Critical path method (CPM)

Identification of Plan Schedule

Maintenance Needs Maintenance Maintenance

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Analyse for Execute
Record History
Improvement Maintenance

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 SoMMME
Department of Mechanical Engineering

Thank You
for
Your Kind Attention!

© Juni 18 MuD Universität Paderborn

Dr.-Ing. James Kuria Kimotho Department of Mechanical Engineering
jkuria@eng.jkuat.ac.ke JKUAT
P.O. Box 62000-00200
Nairobi