Week 9-10 Maintenance Technics

Maintenance Concepts
❖Maintenance and reliability is important

❖Maintenance and product quality
❖Maintenance and productivity
❖Maintenance and safety
❖Maintenance and supply chain
❖Failure cause disruption, waste, accident,
inconvenience and expensive
Failure
❖Failure – inability to produce work in appropriate
manner
❖Equipment / machine failure on production floor
– worn out bearing, pump, pressure leaks,
broken shaft, overheated machine etc.
❖Equipment failure in office – failure of power
supply, air-conditioned system, computer
network, photocopy machine
❖Vehicle failure – brake, transmission, engine,
cooling system
Maintenance
The primary goal of maintenance is to avoid
or mitigate the consequences of failure of
equipment.
❖This may be by preventing the failure
before it occurs which preventive
maintenance PM and condition-based
maintenance help to achieve.
❖It is designed to preserve and restore
equipment reliability by replacing worn
components before they fail.
Dr. Walid Abdelghaffar
Reliability
(MTBF) Product
quality Service
Environment
delivery
managemen
t
(SDM)
Repair
time
(MTTR)
The role of maintenance &

Asset management
Safety
Availability Throughput
rate
Cost

Total Cost of Maintenance
Direct Indirect
Costs
Equipment
Costs
• Excess Downtime
• Labors • Lost Sales
• Spares • Surplus Equipment
• Subcontractors
Total Cost of Maintenance

Maintenance Iceburg

Managing Risk for Minimum Cost
and Maximum Performance
Equipment
performance
Cost
Best
Poor Maintenance practices

What are People in business
for?
❖To make money
Good maintenance means better use of

money

Our Use of Money is measured by Financial
Performance Indicators (FPI's):
Return on investment
Profitability Cashflow

How good maintenance
enhances overall company
performance
❖ Stable plant operations minimizes feed stock needs
❖ Company image enhanced by good performance and
on-time order deliveries
❖ Efficient resource use reduces direct costs
❖ Risk- based approach minimizes costs
❖ Overall life cost of facilities minimized
❖ All this means increased company performance in

terms of profitability and cashflow, and long-term
improvements in ROI.
Maintenance Types
RCM Preventive
TPM
Run to Failure Design Out

Maintenance Types

Corrective Maintenance CM
Sometimes called:
- Repair
- Run to failure
- Breakdown Maintenance
It is conducted to get equipment working again.
If you practice Breakdown Maintenance, a

day may come when your machines may break
down your company.

Preventive Maintenance (PM)
❖It is the anticipation of failures and adoption of

necessary preventive actions before they occur.
Why Preventive Maintenance should be done?
▪ To Prevent Failure
▪ To detect Early Failure
▪ To Discover a Hidden Failure

PM :Time-based Maintenance
- is labor intensive, ineffective in identifying problems that
develop between scheduled inspections, and is not cost-
effective.
- It is called Periodic Maintenance
• If a man (who does not know how
to swim) tries to wade through a
river simply with the knowledge
that the average depth of the river
is less than his height, chances are
he may drown.
• Similarly, if you practice machine

maintenance purely based on
averages and statistics, your
company may sink.

PM: A Condition Based
Maintenance
❖ Greatly reduced maintenance and operating costs.
❖ Improved machine productivity.
❖ Longer machine life.
❖ Improved operational safety.
❖ It is called Predictive Maintenance
Sit back and relax.
Let professionals take care of
your machine maintenance.
Adopt condition monitoring
based Predictive Maintenance
practices for improved
machine health.

Benefits Of Preventive
Maintenance
❖Prevention of downtime
❖Extension of the useful life of the instrument
❖Less probability of a costly breakdown
❖More reliable instrument
❖Increased likelihood that the instrument will
maintain it’s operational specifications
❖Minimization of potential contamination issues
❖A safer instrument for staff

Tradeoff Between Repairs and PM
Annual Cost ($)
Minimum Total
Maintenance Cost
Total
Maintenance
Costs
Minimum
Level of Preventive
Preventive Maintenance
Maintenance Cost
Breakdown
and Repair
Cost
Degree of Preventive Maintenance
Maintenance Types - Comparative Cost
Direct Design Out
cost
Preventive
Predictive
Preventive
Predictive
Opportunity
Overtime Run to
Preventive maint direct
costs increases failure
Predictive maint direct
costs decreases
+ effectiveness increases
Indirect cost

Impact of Technology Hard
functionality
Cost of and Software
Means technology
is becoming cost
effective for a
wider range of
equipment
1960 Sophistication of technology 2023

Proactive Maintenance
▪ Maintenance done in response to Root Cause Failure

Analysis.
▪ It is called design out maintenance
▪ If you are finding the same bearing going bad every 2
months, wouldn’t you want to know why?

RELIABILITY CENTERED MAINTENANCE
(RCM)
RCM is a powerful systematic methodology for maintenance
management to improve the system reliability and utilization.
RCM is a process used to determine the maintenance

requirements of any physical asset in its operating context.
In many RCM applications the plant already has effective

maintenance programs.
The RCM projects therefore be an upgrade projects, identify and

select the most effective PM tasks, to recommend new tasks or
revisions , and to eliminate ineffective tasks then apply this
changes within the existing programs in a way that will allow
the most efficient allocation of resources.

Reliability Centered Maintenance

Benefits of RCM
❖Improve operating performance.
❖Improve quality
❖Greater maintenance cost effectiveness
❖Increase equipment life
❖Better teamwork
❖Increase moral

Reliability Centered Maintenance
Where does CBM fit with RCM
❖Reliability Centered Maintenance is a

dynamic process which seeks to accumulate
and integrate Both historical and real – time
data, knowledge and experience to make
optimal maintenance decision based on a
balancing of Cost, Risk and Performance
considering both the probability of failures CBM
Provides Historical & Live Data
and the consequences CBM Provides Historical &
Live Data
29 Dr. Walid Abdelghaffar

Performance Measures
Pyramid
MTBF = Mean Time Between Failure
MTTR = Mean Time to Repair
Business
measures
Quality Rate of
working
Availability
MTBF MTTR
Customer Lit/hr GM/ hour

Yield
complains
TOTAL PRODUCTIVE MAINTENANCE (TPM)
TPM is an integrated approach to the maintenance
management.
TPM is an equipment maintenance philosophy utilizing

systematic maintenance procedures supported by
clearly defined policies and procedures.
TPM: is:
Total Productive Management
Overall Management
The objectives of TPM are to create an active

participation of all employees in maintenance factions.
TPM focuses on reducing machine downtime,
improving product quality, and preplanning of
maintenance functions.

Risk based maintenance
❖RISK can be defined as “the threat or probability
that an action or event will adversely or
beneficially affect an organization's ability to
achieve its objectives”.
❖In simple terms risk is ‘Uncertainty of Outcome’,

either from pursuing a future positive
opportunity, or an existing negative threat in
trying to achieve a current objective.

Criticality/Severity Categories
Ranking Effect Comment
No reason to expect failure to have any effect on safety, health, environment,
1 None
or mission.
Minor disruption to facility function. Repair to failure can be accomplished
2 Very Low
during trouble call.
Minor disruption to facility function. Repair to failure may be longer than
3 Low
trouble call but does not delay mission.
Low to Moderate disruption to facility function. Some portion of mission may need to
4
Moderate be reworked or process delayed.
Moderate disruption to facility function. 100% of mission may need to be
5 Moderate
reworked or process delayed.
Moderate Moderate disruption to facility function. Some portion of mission is lost.
6
to High Moderate delay in restoring function.
High disruption to facility function. Some portion of mission is lost. Significant
7 High
delay in restoring function.
High disruption to facility function. All of mission is lost. Significant delay in
8 Very High
restoring function.
Potential safety, health, or environmental issue. Failure will occur with
9 Hazard
warning.
High Potential safety, health, or environmental issue. Failure will occur without
10
Hazard warning.
A simple 7-step of risk-based maintenance
❖Step 1 - Identify all Failure Modes
▪ Select a system and break it down into

maintenance significant items. Establishing
the failure modes for each item.
▪ For example, consider a tire. What could go
wrong with it?
▪ It could burst
▪ Go flat
▪ Go bald in the center
▪ Go bald at the edge, etc.

❖Step 2 - Establish the Cause of Each Failure
▪ What could cause each failure mode? For

example, why would tires go bald at the
edge? The tracking could need adjusting or
the ball-joints could be worn.

❖Step 3 - Establish the Effect of Each Failure
▪ What would happen if a certain failure mode

occurred?
▪ What would happen if a tire went bald at the
edge? Consider a lorry in a quarry. It might be
able to continue off-road in a reduced
capacity. Use on the road might be prohibited.

❖Step 4 - Establish the Probability of Each

Failure
▪ What is the likelihood of each failure.

▪ For example, in the lorry's lifetime how many
times will it need its tracking adjusting?
▪ What is the likelihood that a ball joint will go?

❖Step 5 - Identify Different Repair Tasks
▪ How many ways are there to repair each

problem? For example, how could you repair
a tire that has gone bald on one side? You
could:
▪ Buy another tire
▪ Get a tire cutting company to recut the tread
▪ Recut the tread yourself.

❖Step 6 - Conduct Level of Repair Analysis

(LORA)
▪ Trade-off each maintenance policy using the data you

have gathered.
▪ For example:
• a new tire might cost $1,500
• it might cost $10,000 to set up a facility to recut tires
and cost $50 per repair, or
• it might cost $250 to have it done in a garage.
• Option (1) would cost more than (3) and if we expected
to recut 50 tires or more then (2) would be the cheapest
option.
❖Step 7 - Carry Out A Detailed Maintenance

Task Analysis (MTA)
▪ Finally, carry out maintenance task analysis.

▪ Define every step in the repair procedure. For
example, consider the maintenance steps in the
removal of a lorry wheel.
▪ Find level ground.
▪ Jack up the lorry.
▪ Undo the nuts.
▪ Remove the wheel.
▪ This has shown that we will need a suitable jack and
wrench. We might also need a repair shop, a manual
and two men to lift the wheel. They might also need to
go on a special training course, and of course they
will need recoverable and disposable spare parts.
Computerized Maintenance Management
Systems (CMMS)
❖CMMS provides a way for companies to track
equipment and inventory assets, detail when
and how work orders are to be performed in
maintaining those assets, and accumulate all
the associated costs for labor, materials and
tools.

Who needs CMMS?
❖Maintenance Departments of Large
Organizations
❖Help Desks / Call Centers
❖IT Departments

What is CMMS?
▪ CMMS allow companies to electronically track orders
for work (work orders) within a centralized software
package.
▪ Work orders are created by a call center operator who
takes calls from employees or customers out in the
field (example: “My room is too hot!”).
▪ A work order has a number assigned to it for tracking.
▪ A work order administrator can assign specific
maintenance workers to the tasks under the work
order.
▪ Materials (inventory items) and tools that may be
needed for the job are also assigned.
What is CMMS?
▪ A work order goes through several stages called status.
▪ It must first be “approved” by a maintenance administrator
before becoming an active work order (“in progress”).
▪ Once the workers complete the work, it will be “completed”
and later “closed”.
▪ Workers can enter how much time they spend performing
the work against a work order (called “labor reporting”).
▪ This allows the systems to rollup costs for the labor against
a work order.

What is CMMS?
▪ A work order typically has several tasks under
it (for example, change oil, rotate tires, check
fluids, etc…). This collection of tasks or
operations can be referred to as a “Job Plan”.
▪ When a work order is created, it can be

associated with a pre-existing job plan. This
makes it much easier to define what is to be
done on a work order.
▪ Work orders can also be automatically created

by the CMMS through PMs (preventive
maintenance).
What is CMMS?
▪ PM’s are essentially a listing of work
orders that have to be performed at a
certain time interval or based on some
meter reading.
▪ An example would include changing the

oil in your car every 3 months OR every
3000 miles. The PMs in a CMMS
typically generate tens or hundreds of
work orders every week.

What is CMMS?
▪ Usually, CMMS packages allow the users to
track and enter all the equipment
(sometimes called assets) at the facility.
▪ This makes it easier to select what needs to

be worked on when a work order is created.
▪ The call center operators can select the

equipment directly from the list.

What is CMMS?
▪ The same is also true for “locations”.
Often, the whole facility is modeled in
some manner in the software.
▪ Thus, the operator may select a

building, a floor, a room, and within
that room, a piece of equipment that is
having problems and needs to be
fixed.
What is CMMS?
▪ It can be a complex task keeping track of
items in an inventory and thus the software
assists greatly in this manner.
▪ Also, this allows the work order

administrators to choose from a list of
materials in the system which items will be
needed to do the work.

What is CMMS?
▪ Inventories are typically made up of
storerooms at one or more locations, items in
the storeroom (which have unique numbers),
and the bins that the materials reside in (like a
hopper full of bolts).
▪ A list of Companies is also maintained in the

software. This allows users to choose
manufacturers for equipment or materials, and
aids in the purchasing of more materials.
What is CMMS?
▪ The purchasing of materials goes through
several stages.
▪ Usually, when a part runs low (typically because
the work orders are reserving and using the
parts), more have to be ordered to refill the bins.
▪ This often starts with a PR (Purchase Request)
that has to be approved by a designated person.
▪ Once approved, the PR becomes a PO
(Purchase Order).

What is CMMS?
▪ The PO consists of a list of materials that
need to be purchased, and in what
quantities.
▪ When several vendors are involved, the
process becomes even more complicated.
▪ Most CMMS packages help manage the
whole process of purchasing and tracking
all of the costs associated with it.

What is CMMS?
▪ Finally, most systems have to keep track of the labors and
users of the system, thus information can be stored about
people such as salaries and what groups they belong to
(such as electricians, mechanics, etc…).
▪ The task of configuring a CMMS can take months to

accomplish.
▪ In fact, many systems don’t become operational for as long

as a year and don’t operate smoothly or mature for several
years.
What is CMMS?
▪ The installation of a CMMS can go as quickly
as a week, but no useful information will be
in the system.
▪ This is what makes implementation of CMMS

packages very complicated.

What is CMMS?
▪ Most systems also utilize Client-Server Database
technologies (Oracle, SQL Server, SQLBase) to
distribute information to everyone’s workstation.
▪ These systems are also not trivial to configure

especially in existing IT infrastructures where many
rules and limitations may apply.

How Can CMMS Save Money?
Most large companies cannot remain
competitive without a computerized
maintenance management system.

▪ Eliminates the nightmare of
paperwork.
▪ Companies still tend to print out work

orders for the maintenance personnel
for convenience, but the software can
organize these records and make lost
work orders a thing of the past.

▪ Helps maintenance departments move from
doing corrective maintenance to preventive
maintenance which not only keeps the
organization running more smoothly but impacts
safety and quality of life.
▪ Generally, it is much less expensive to maintain

something than it is to fix it after it breaks.
▪ It also extends the life of the equipment.

▪ Makes work force more efficient.
▪ It helps workers plan their efforts.
▪ They spend less time tracking their work and more time
fixing equipment.
▪ If each worker saves an hour every day (which is typical),

the savings for a large maintenance department can be in
the hundreds of thousands of pounds.

❖Produces a variety of automated reports that
can be analyzed to increase efficiency in
these areas:
1.Reduce obsolete inventory materials (it
costs money to store materials/parts that
are no longer needed for maintenance)
2.Reduce the amount of material that has to
be stored to do maintenance (it’s easier to
reorder more often when its automated,
thus lowering balances)

3. Track costs for materials from different
vendors
4. Monitor efficiency of personnel
5. Look for ways to improve processes
through standardization and repetition
6. Automatically produce compliance
reports (for example, to meet certain
government standards for safety)

MAINTENANCE PLANNING AND
SCHEDULING
❖ Effective planning and scheduling contribute significantly to the
following:
• Reduced maintenance cost.

• Improved utilization of the maintenance workforce by
reducing delays and interruptions.
• Improved quality of maintenance work by adopting the best
methods and procedures and assigning the most qualified
workers for the job.
Planning and Scheduling
Objectives
❖ Minimizing the idle time of maintenance workers.
❖ Maximizing the efficient use of work time, material,

and equipment.
❖ Maintaining the operating equipment at a responsive

level to the need of production in terms of delivery
schedule and quality.
Planning
Planning is the process by which the elements required
to perform a task are determined in advance of the job
start.
❖ It comprises all the functions related to the
preparation of:
1. The work order
2. Bill of material
3. Purchase requisition
4. Necessary drawings
5. Labor planning sheet including standard times
6. All data needed prior to scheduling and releasing
the work order.
❖ Good planning is a prerequisite for sound
scheduling.
Planning Procedures
❖ Determine the job content.
❖ Develop work plan. This entails the sequence of the activities in
the job and establishing the best methods and procedures to
accomplish the job.
❖ Establish crew size for the job.
❖ Plan and order parts and material.
❖ Check if special tools and equipment are needed and obtain them.
❖ Assign workers with appropriate skills.
❖ Review safety procedures.
❖ Set priorities for all maintenance work.
❖ Assign cost accounts.
❖ Complete the work order.
❖ Review the backlog and develop plans for controlling it.
❖ Predict the maintenance load using effective forecasting technique.
Basic Levels of Planning Process
(Depend on The Planning Horizon)
1. Long-rang planning: it covers a period of 3 to 5 years
and sets plans for future activities and long-range
improvement.
2. Medium-range planning: it covers a period of 1 month

to 1 year.
3. Short-rang planning: it covers a period of 1 day to 1

week. It focuses on the determination of all the
elements required to perform maintenance tasks in
advance.
Long and Medium-Range Planning
Needs to utilize the following:
1. Sound forecasting techniques to estimate the maintenance load.
2. Reliable job standards times to estimate staffing requirements.
3. Aggregate planning tools such as linear programming to
determine resource requirements.
❖ Long-Range Planning sets plans for future activities and long-
range improvement.
❖ Medium-Range Planning Specify how the maintenance
workers will operate:
• Provide details of major overhauls, construction jobs,
preventive maintenance plans, and plant shutdowns.
• Balances the need for staffing over the period covered.
• Estimates required spare parts and material acquisition.
❖ Short-Range Planning focuses on the determination of all the
elements required to perform maintenance tasks in advance.
Scheduling
It is the process by which jobs are matched with resources
and sequenced to be executed at a certain points in time.
• Scheduling deals with the specific time and phasing

of planned jobs together with the orders to perform
the work, monitoring the work, controlling it, and
reporting on job progress.
• Successful planning needs a feedback from

scheduling.
Reliable Schedule Must Take Into
Consideration
❖A job priority ranking reflecting the

criticality of the job.
❖The availability of all materials needed
for the work order in the plant.
❖The production master schedule.
❖Realistic estimates and what is likely to
happen.
❖Flexibility in the schedule.
Maintenance Schedule Can be
Prepared at Three Levels
1. Long-range (master) schedule
2. Weekly schedule
3. Daily schedule
Long-Range (master) Schedule
❖ Covering a period of 3 months to 1 year.
❖ Based on existing maintenance work orders (blanket
work order, backlog, PM, anticipated EM).
❖ Balancing long-term demand for maintenance work with
available resources.
❖ Spare parts and material could be identified and ordered
in advance.
❖ Subject to revision and updating to reflect changes in the
plans and maintenance work.
Weekly Schedule
❖ Covering 1 week.
❖ Generated from the master schedule.
❖ Takes into account current operations schedules and
economic considerations.
❖ Allow 10% to 15% of the workforce to be available for
emergency work.
❖ The schedule prepared for the current week and the
following one in order to consider the available
backlog.
❖ The work orders scheduled in this week are
sequenced based in priority.
❖ CPM and integer programming techniques can be
used to generate a schedule.
Daily Schedule
❖Covering 1 day.
❖Generated from weekly
schedule.
❖Prepared the day before.
❖Interrupted to perform EM.
❖Priorities are used to schedule
the jobs.
Scheduling Procedures (Steps)
1. Sort backlog work orders by crafts.

2. Arrange orders by priority.
3. Compile a list of completed and carry over jobs.
4. Consider job duration, location, travel distance, and
the possibility of combining jobs in the same area.
5. Schedule multi-craft jobs to start at the beginning of
every shift.
6. Issue a daily schedule (not for shutdown
maintenance).
7. Authorize a supervisor to make work assignments
(dispatching).
Maintenance Job Priority System
❖ Priorities are established to ensure that the most critical

work is scheduled first.
❖ It is developed under coordination with operations staff.
❖ It should be dynamic.
❖ It must be updated periodically to reflect changes in

operation and maintenance strategies.
❖ It typically includes three to ten levels of priority.

Scheduling Techniques
The objective of the scheduling techniques is to construct a

time chart showing:
• The start and finish for each job.

• The interdependencies among jobs.
• The critical jobs that require special attention and
effective monitoring.
Maintenance Performance
Employee Maintenance
Involvement Procedures
© 1995 Corel
Corp.
Maintenance
Performance
© 1995 Corel Corp.

Employee Involvement
➢ Information sharing
➢ Skill training
➢ Reward system
➢ Power sharing
Maintenance Procedures
➢ Clean and lubricate
➢ Monitor and adjust
➢ Minor repair
➢ Computerized records
Evaluating Maintenance
➢ Reliability
◼Probability that an item will function for a given time
➢ Mean time between failures (MTBF)
◼Average time between failures of a repairable item
➢ Failure rate
◼Reciprocal of MTBF
Failure Rate (%)
FR(%) =Number of failures

Number of units tested
❖ Lifetime Failure Rates
“normal” failure Wearout
failure
Failure
rate Infant
mortality
and
improper use
failure
Lifetime
• Mean Time Between Failures =1/FR(N)
• Failures per Operating Hour= (Number of failures)/

operating time
Return On Investment (ROI)
❖Return On Investment (ROI) =
Profit
(fixed capital + working capital)

Return on investment
calculation
- Gross
Total sales
margin
TRADING
Raw material costs - PROFIT
Fixed expenses
+
Total
Other expenses expenses
/ ROI
+
Stocks
Working
Debtors capital
-
NET
Creditors +
ASSETS
Land building plant Fixed
equipment assets

Week 9-10 Maintenance Technics

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Maintenance Concepts

❖Maintenance and reliability is important

The role of maintenance &

Dr. Walid Abdelghaffar

Total Cost of Maintenance

Dr. Walid Abdelghaffar

Dr. Walid Abdelghaffar

Dr. Walid Abdelghaffar

❖To make money

Good maintenance means better use of

Dr. Walid Abdelghaffar

Dr. Walid Abdelghaffar

❖ All this means increased company performance in

Run to Failure Design Out

Dr. Walid Abdelghaffar

Dr. Walid Abdelghaffar

If you practice Breakdown Maintenance, a

Dr. Walid Abdelghaffar

❖It is the anticipation of failures and adoption of

Why Preventive Maintenance should be done?

Dr. Walid Abdelghaffar

• Similarly, if you practice machine

Dr. Walid Abdelghaffar

Dr. Walid Abdelghaffar

Dr. Walid Abdelghaffar

Annual Cost ($)

Dr. Walid Abdelghaffar

1960 Sophistication of technology 2023

Dr. Walid Abdelghaffar

▪ Maintenance done in response to Root Cause Failure

Dr. Walid Abdelghaffar

RCM is a process used to determine the maintenance

In many RCM applications the plant already has effective

The RCM projects therefore be an upgrade projects, identify and

Dr. Walid Abdelghaffar

Dr. Walid Abdelghaffar

Dr. Walid Abdelghaffar

❖Reliability Centered Maintenance is a

29 Dr. Walid Abdelghaffar

Customer Lit/hr GM/ hour

TPM is an equipment maintenance philosophy utilizing

The objectives of TPM are to create an active

Dr. Walid Abdelghaffar

❖In simple terms risk is ‘Uncertainty of Outcome’,

Dr. Walid Abdelghaffar

❖Step 1 - Identify all Failure Modes

▪ Select a system and break it down into

Dr. Walid Abdelghaffar

❖Step 2 - Establish the Cause of Each Failure

▪ What could cause each failure mode? For

Dr. Walid Abdelghaffar

❖Step 3 - Establish the Effect of Each Failure

▪ What would happen if a certain failure mode

Dr. Walid Abdelghaffar

❖Step 4 - Establish the Probability of Each

▪ What is the likelihood of each failure.

Dr. Walid Abdelghaffar

❖Step 5 - Identify Different Repair Tasks

▪ How many ways are there to repair each

Dr. Walid Abdelghaffar

❖Step 6 - Conduct Level of Repair Analysis

▪ Trade-off each maintenance policy using the data you

❖Step 7 - Carry Out A Detailed Maintenance

▪ Finally, carry out maintenance task analysis.