kfupm.edu.

sa

ISE 510 Maintenance Systems

Management
Dr. Salih Duffuaa
Course Objectives

Describe the role maintenance plays in an organization.

Explain the different maintenance strategies and their
application.
Present techniques to Determine the optimal preventive
maintenance interval and inspections time.measures
(PIs),
Present the role of maintenance resources control for
maintenance as service in the aftersales market including
life cycle costing.
Cover techniques that improve maintenance Systems
Performance.
King Fahd University of Petroleum & Minerals
kfupm.edu.sa
Course Outcomes

Describe the different components of a maintenance system in an

organisation.
Describe the role of maintenance resources control for
maintenance as service in the aftersales market.(knowledge)
Justify the use of a maintenance strategies and concepts
including TPM and RCM and how to apply them in practice.
Determine the optimal maintenance recourses, the
replacement interval, and inspections time. (skills)
Estimate the maintenance jobs standard times to upkeep the
work productivity and the overall equipment efficiency (OEE).
Lead teams to plan and execute maintenance activities. (Values)

King Fahd University of Petroleum & Minerals

kfupm.edu.sa
Course description

Maintenance Management Systems, their philosophies, trends

and prospective. Maintenance organization, maintenance strategy
and concepts, including total productive maintenance (TPM) and
Reliability centered maintenance (RCM), forecasting maintenance
load, maintenance capacity planning, preventive maintenance
replacement decision models, maintenance jobs measurement and
standards, quality of maintenance jobs, maintenance productivity
and auditing, maintenance performance measures and
maintenance resources control. Case studies.
 

King Fahd University of Petroleum & Minerals

kfupm.edu.sa
Grading Policy

Homework and attendance 15%

Case study and presentation 10%
Term Project/Term paper 20%
Mid term Exam 25%
Final Exam 30%

 
King Fahd University of Petroleum & Minerals
kfupm.edu.sa
 Lecture 1 objective

1. Enable Students to understand the role of

maintenance in meeting organizational
objectives.

2. Present maintenance as a System that has

activities that require planning,organizing ,
designing, measurement and control

King Fahd University of Petroleum & Minerals

kfupm.edu.sa
Maintenance

Maintenance is defined as the of combination

activities by which equipment or a system is
kept or restored to a state in which it can per
form its designated function. It is an
important factor in product quality control
and can be used as a strategy for successful
competition
King Fahd University of Petroleum & Minerals
kfupm.edu.sa
MAINTENANCE

BS 3811 : 1964 defines Maintenance as :

Work undertaken in order to keep or
restore every facility to an acceptable
working condition/standard.

King Fahd University of Petroleum & Minerals

kfupm.edu.sa
 A system

 A System is a collection of entities/components

that work towards a common objectives.

 Examples:
 Production system.
 Educational System.
 Students provide some

King Fahd University of Petroleum & Minerals

kfupm.edu.sa
 Management


Management is a process of planning, decision
making, organizing, leading, motivation and
controlling the human resources, financial,
physical, and information resources of an
organization to reach its goals efficiently and
effectively

King Fahd University of Petroleum & Minerals

kfupm.edu.sa
Maintenance Versus Organization Objectives

The objectives and goals of an organization

depends on the organization state of mind
and type of business. Some objectives are
Meet or exceed customer satisfaction
Maximizing profit, Meet set targets
Meet set safety standard, Zero product defect
Does Maintenance affect these goals?

King Fahd University of Petroleum & Minerals

kfupm.edu.sa
Role of Maintenance

In any organization Maintenance is the backbone

of all successful enterprises and contributes to:

Costs
Meet Set Targets
Improve Utilization
Improve Equipment Improve Product Quality
Reduce Performance
How? King Fahd University of Petroleum & Minerals
kfupm.edu.sa
Maintenance Versus Organization Objectives

A system is a collection of components

that work together towards a common
objective. Maintenance can be
considered as a system with a set of
activities carried out in parallel with
production systems. A diagrammatic
relationship among organizational
objectives, the production process, and
maintenance is shown in Figure 1.1
King Fahd University of Petroleum & Minerals
kfupm.edu.sa
 Organizational
objectives

Quality Quantity

Delivery

Production
Input process Output

Feedback

King Fahd University of Petroleum & Minerals

kfupm.edu.sa

Production Maintenance Demand for

Maintenance System Output

• A maintenance system can be viewed

as a simple input output model. The
inputs to such a model are labor,
management, tools, spares,
equipment, etc. and the output is
equipment that is up, reliable and well
configured to achieve the planned
operation of the plant.
King Fahd University of Petroleum & Minerals
kfupm.edu.sa
Maintenance System Output

• This enables us to optimize the

resources for maximizing the output
of a maintenance system. A typical
maintenance system is shown in
Figure 1.2. Activities needed to make
this system functional, namely,
planning, organizing, and control, are
shown in this figure
King Fahd University of Petroleum & Minerals
kfupm.edu.sa
Maintenance Planning activities

Planning activities generally include

the following :
1. Maintenance philosophy
2. Maintenance load forecasting
3. Maintenance capacity
4. Maintenance organization
5. Maintenance scheduling.
King Fahd University of Petroleum & Minerals
kfupm.edu.sa
 MAINTENANCE STRATEGIES
(MAINTENANCE FORM)
1.Breakdown Maintenance (Run To Failure)
2. Fault Finding (FF)
3. Time directed Preventive Maintenance(TD)
4. Condition Based Maintenance (CBD)
5. Design Modification (DM)
6. Replacement Instead of Maintenance
7. Planned Replacement (Car Fleet)
8. Opportunity Maintenance
King Fahd University of Petroleum & Minerals
kfupm.edu.sa
 Maintenance strategies

Replacement Overhaul Preventive Design Breakdown/ Fault

maintenance modification corrective or finding
run to failure
Opportunity
Maintenance

Condition Statistically and

based reliability based

Offline Online Time Use

based based
 Maintenance Load Forecasting

Maintenance load is a random variable and

forecasting is the process by which
maintenance load is predicted. Load
forecasting is essential for capacity planning.
Many factors affect the load, they include
equipment age, climate, quality of
maintenance, etc.
King Fahd University of Petroleum & Minerals
kfupm.edu.sa
Maintenance Scheduling
Maintenance scheduling is the
process of assigning resources and
manpower for jobs to be
accomplished at certain times. It is
necessary to ensure that the
needed craftsmen, the parts, and
materials required are available
before a maintenance task can be
scheduled.
King Fahd University of Petroleum & Minerals
kfupm.edu.sa
Maintenance Capacity Planning

Maintenance capacity planning

determines the resources needed to
meet the demand for maintenance
work. Those resources include
manpower, material, spare parts,
equipment, and tools. Critical aspects
of maintenance capacity are the
numbers and skills of craftsmen,
required maintenance tools, etc.

King Fahd University of Petroleum & Minerals

kfupm.edu.sa
Maintenance Organization
Maintenance Organization Depends On
Maintenance Load, Plant Size, Trade
and Skill, Maintenance Could Be
Centralized Or Decentralized Or A
Combination of Both. See Figure 1.5 In
Text Book

King Fahd University of Petroleum & Minerals

kfupm.edu.sa
Organizing Activities

1. Job Design

2. Standard Time

3. Project Management
King Fahd University of Petroleum & Minerals
kfupm.edu.sa
Job Design
Job design, as related to maintenance
work, comprises the work content of
each job and deter­mines the method
that is to be used, special tools needed,
and the skilled persons required.

King Fahd University of Petroleum & Minerals

kfupm.edu.sa
Time Standards
Time Standards are Needed For
Effective Planning. It is The Time That
Takes A Qualified Worker Worker At
100% Pace To Complete The Job.
Techniques Used For Developing Time
standards Are Work Measurement,
Work Sampling. Estimation and Slotting

King Fahd University of Petroleum & Minerals

kfupm.edu.sa
Project Management

Techniques Such As CPM, PERT Are

Needed For Large Jobs Such as
Overhauls.
They will Enable Better Control OF
Cost and work. They Usually
Results In Better Utilization Of
Resources
King Fahd University of Petroleum & Minerals
kfupm.edu.sa
Control activities
Control is an essential part of Scientific
management. control as applied to
maintenance includes:
1. Work control
2. Inventory control
3. Cost control
4. Quality control
King Fahd University of Petroleum & Minerals
kfupm.edu.sa
 Work Control
.

The management and control of the maintenance work

is essential for achieving set plans. The work order
system is the tool used for controlling the
maintenance work. A well-designed work order with
a sound reporting system is the heart of the
maintenance system The essential tools for effective
control of the maintenance work including the design
of a work order are covered in chapter 6.
King Fahd University of Petroleum & Minerals
kfupm.edu.sa
 Inventory Control

Material and spare parts are essential for

maintenance work. Prior to scheduling
maintenance work spare parts must be
available. Techniques for inventory
control are covered in chapter 5 of the
text.

King Fahd University of Petroleum & Minerals

kfupm.edu.sa
MAINTENANCE COSTS.

1. DIRECT COSTS
• Cost of Periodic Inspection
• Service Cost
• Repair Cost, Overhaul Cost

2. STAND-BY COSTS
• Cost of Operating and Maintaining a Standby Unit

King Fahd University of Petroleum & Minerals

kfupm.edu.sa
MAINTENANCE COSTS.

3. LOST PRODUCTION COSTS :

• Cost due to Equipment down time.

4. DEGRADATION COST
• Cost occurring due to deterioration of the life span of
equipment due to no maintenance or inadequate
maintenance.

King Fahd University of Petroleum & Minerals

kfupm.edu.sa
Cost Control

The control of maintenance cost optimizes

all the costs in maintenance, while
achieving, set organizational objectives such
as: availability, “Quality Rate”, and other
efficiency and effectiveness measures. Cost
reduction and control can be used as an
edge for competition in providing products
and services. The issues related to cost and
its control are presented in chapters 6 and
King Fahd University of Petroleum & Minerals

9. kfupm.edu.sa
Quality Control

In the case of maintenance work "doing it

right the first time" is very essential. Quality
may be assessed as the percentage of
accepted maintenance jobs according to
the standard adopted by the organization.
High Quality is usually assured by checking
the critical maintenance jobs or by
maintenance supervision. The details of
maintenance quality control are presented
in chapter 8. King Fahd University of Petroleum & Minerals
kfupm.edu.sa
Managing For Quality and Training

Managing for quality is a managerial

responsibility.. The key for managing
for quality lies first in the awareness
of the need to improve and second
in selecting appropriate
improvement techniques. Chapter
14 focuses on the aspects of
continuous improvement.
King Fahd University of Petroleum & Minerals
kfupm.edu.sa
Human Behavior

Managers should try to know how the

behavior of subordinates can affect
management's planning, organizing,
and controlling actions. In maintenance
decision making, behavior of
subordinates should be of interest to
management. It should be ensured that
the desired level of craftsmen
satisfaction is achieved and maintained.
King Fahd University of Petroleum & Minerals
kfupm.edu.sa
Maintenance Terms
Availability: The ability of an
equipment to successfully perform its
required function at a stated instant of
time or over a stated period of time.

Breakdown: Failure resulting in the

non-availability of an equipment.

King Fahd University of Petroleum & Minerals

kfupm.edu.sa
Maintenance Terms

Condition-based maintenance: The

preventive maintenance initiated as a result
of knowledge of the condition of an
equipment observed through routine or
continuous monitoring.

Condition monitoring: The continuous or

periodic measurement and interpretation of
data to infer the condition of an equipment
to determine its need for maintenance.

King Fahd University of Petroleum & Minerals

kfupm.edu.sa
Maintenance Terms

Corrective maintenance: The

maintenance carried out after a failure
has occurred and intended to restore an
equipment to a state in which it can
perform its required function.

Emergency maintenance: That

maintenance which is necessary in order
to avoid serious consequences, such as
loss of production time and unsafe
conditions King Fahd University of Petroleum & Minerals
kfupm.edu.sa
Maintenance Terms
Failure: The termination of the ability
of an equipment to perform its
required function.

Fault: An unexpected deviation from

requirements which require corrective
action.

King Fahd University of Petroleum & Minerals

kfupm.edu.sa
Maintenance Terms
Feedback: A report on the success
or failure of an action to achieve its
desired objectives and which can be
used to improve a process.

Forced outage: Outage due to the

unscheduled stopping of equipment.

King Fahd University of Petroleum & Minerals

kfupm.edu.sa
Maintenance Terms
Inspection: The process of measuring,
examining, testing, gauging or otherwise
detecting any deviations from specifications.

Maintainability: The ability of an equipment,

under stated conditions of use, to be
retained in, or restored to, a state in which it
can perform its required function, when
maintenance is performed under stated
conditions and using prescribed procedures
and resources
King Fahd University of Petroleum & Minerals
kfupm.edu.sa
Maintenance Terms
Maintenance: The combination of all
technical and and associated actions by
which an equipment or a system is kept
or restored to a state in which it can
perform its designated functions.

Maintenance history: A history record

showing repair, spares, etc. used to
assist maintenance planning.
King Fahd University of Petroleum & Minerals
kfupm.edu.sa
Maintenance Terms
Maintenance schedule: A
comprehensive list of items and the
maintenance tasks required, including
the intervals at which maintenance
should be performed.

Planned maintenance: The

maintenance organized and carried
out with forethought, control, and the
use of records to meet a
predetermined plan
King Fahd University of Petroleum & Minerals
kfupm.edu.sa
Maintenance Terms
Overhaul: A comprehensive examination
and restoration of an equipment, or a major
part thereof, to an acceptable condition.

Preventive maintenance: The

maintenance carried out at predetermined
intervals or intended to minimize the
probability of failure or the performance
degradation of equipment.

King Fahd University of Petroleum & Minerals

kfupm.edu.sa
Maintenance Terms

Refurbishment: Extensive work intended

to bring equipment up to acceptable
functional conditions, often involving
improvements.

Repair:To restore an item to an

acceptable condition by the renewal,
replacement or replacement of
damaged or worn parts. King Fahd University of Petroleum & Minerals
kfupm.edu.sa
Maintenance Terms

Restoration: Maintenance actions

intended to bring back equipment to
its original conditions

Running maintenance: Maintenance

which can be carried out whilst the
equipment is in service.

King Fahd University of Petroleum & Minerals

kfupm.edu.sa
Maintenance Terms
Shut down maintenance:
Maintenance which can only be
carried out when the equipment is out
of service.

Spare stock: Items which are available

for maintenance purposes or for the
replacement of defective parts.

King Fahd University of Petroleum & Minerals

kfupm.edu.sa
Maintenance Terms
Work order: A written instruction
giving detail of work to be carried out
including detail of spares, manpower,
etc.

Work requisition: A document

requesting work to be carried out

King Fahd University of Petroleum & Minerals

kfupm.edu.sa
Maintenance Terms

Work specification: A document

describing the way in which the work is to
be carried out. It may define the materials,
tools, time standards, and procedures.

King Fahd University of Petroleum & Minerals

kfupm.edu.sa