CHAPTER 8

Maintenance Planning
Maintenance plan is needed to:
 lay down a rational basis for formulating a programme of preventive
maintenance, and
 provide guidelines for corrective maintenance by the adoption of the proper
maintenance policies for the constituent items and components.
Any rational maintenance plan should be related to the production programme of
the plant.
Reasons for introducing a maintenance
planning
Proper maintenance planning protects investment on
machinery, plant and buildings through adequate
maintenance,
 Maintenance planning minimizes waste of spares and
materials;
Good maintenance planning ensures right distribution of
technical information;
Good maintenance planning facilitates plant control; and
expedites evaluation of plant performance
Plant subdivision according to responsibility
• Division of responsibility is obligatory because replacement
strategy for units (or the main plant itself) is influenced by:
external factors (obsolescence, sales, capital cost) and
internal factors, mostly short term such as maintenance
cost, operating cost.
• Replacement strategy at this level is considered as a part of
the corporate strategy.
• In the lower level, repair/replacement strategy is the
responsibility of maintenance management.
Maintenance Policies

• The major maintenance policies which can be classified as corrective

and preventive are the following:
i) Fixed time maintenance (PM)
ii) Condition-based maintenance (PM)
iii) Operate to failure (CM)
iv) Opportunity maintenance
v) Design-out maintenance
vi) Total Productive Maintenance
vii) Contract maintenance
 Total Productive Maintenance
• The concept of total productive maintenance has
grown with automation of manufacturing processes in
which maintenance of the large number of automated
facilities became impossible for maintenance crews.
• The basic concept is
change attitude and improve skill of all personnel;
train operators in maintenance skills and knowledge;
operators maintain the equipment they use.
Goals and Operational aims of TPM
TPM has two goals:
Zero Breakdowns
Zero Defects
• The closer one gets to these objectives, the lower the
costs become, reserves are reduced and work
productivity increases.
Operational aims of TPM are:
Reducing the size of the cause of the fault.
Reducing the frequency of the appearance of the
cause.
Reducing the growth speed of the stress.
Learning how to recognize and eliminate the cause
BEFORE the fault shows itself.
Reducing the total intervention costs
(Maintainability).
Increasing the strength of the component (Robust
Design).
TPM requires different approach to achieve the
overall goals
• Managers are typically process and results oriented and leave equipment
management to the maintenance department.
• With TPM Managers will need to change to:
managing the equipment.
the process and the results.
 Elimination of eight big losses
• Experience inside manufacturing companies has taught that there are eight
families of losses which reduce the efficiency of plant and machinery.
• The TPM objectives for each of the families of loss are:
losses objective
Loss from Breakdown To reduce stoppages due to breakdown to a minimum
Set up Loss To reduce the set up time to less than 10 minutes
Production to minimize effects of supply and demand requirements on production
Adjustment Loss rates.
Small Stoppage Loss To reduce them to zero
Defect Loss To make acceptability limits very tight, 0.1 percent to 0.
Start up Loss To minimize it so that it does not account for more than 0.1 percent of
the lot.
Reprocessing Loss Reduce non-conforming products to almost zero
Process Shut down time due to external factors such as defective materials,
Failure Loss operating errors etc. to be reduced to minimum
Contract maintenance
• Experienced and specialized maintenance personnel
capable of servicing complex plant/equipment are
expensive to retain on full-time basis.
• In such cases, contract maintenance can be a good
solution.
• Contract maintenance can be helpful in:
reducing downtime
reduces carrying of trained manpower required occasionally
eliminates acquisition of complex and very expensive equipment
Determination of Maintenance Plan
• The maintenance plan set should be the best combination
of the above policies.
• Factors that should be considered are:
1) A plant should be classified in to units, items and
components
Simple replaceable items: maintenance is deterministic and
expensive.
Complex replaceable items: maintenance probabilistic and costly.
non-replaceable items: no predetermined maintenance action
required
2) Acquisition of information which might be relevant to
maintenance planning is essential for every unit of plant.
• production pattern: continuous, intermittent, etc.
• nature of the process: chemical, mechanical, etc.
• manufacturer’s maintenance recommendations: actions, periodicities,
etc.
• equipment factors which assist prediction of maintenance work: failure
characteristics, meantime to failure, mode of failure, failure rate, etc.
• economic factors which assist prediction of main critical units:
consequences of failure, cost of replacement prior to failure,
monitoring cost,etc.
• safety factors which place constraints on the decision: internal,
environmental, statutory regulations, etc.
3) The selection of the ‘best’ maintenance policy is
affected by other factors, out of which minimum cost is
the criterion generally adopted for selection of the
appropriate policy given that the safety and
environmental criteria are met;
i.e. the ‘best’ policy for each item is determined from among
identified applicable policies based on minimum cost criterion,
given that the safety and environmental criteria are satisfied.
 Assessment of Potential Effectiveness of
Maintenance Actions
• The potential
effectiveness of a
maintenance action
used has to be
assessed if it can meet
the requirements.
• An example for
assessing the
effectiveness of a plan
adopted is given in the
sketch below.
In maintenance planning, the following guidelines
should be considered in setting a reasonable and
appropriate maintenance policy.
1. A fixed-time replacement policy is usually most suitable for low-
cost simple-replaceable items.
2. A condition-based policy is usually most effective for high-cost
complex-replaceable items.
3. All high cost maintenance items, replaceable or non replaceable,
should be considered for designing out.
4. Where no preventive maintenance or design-out action is
effective or desirable, the item is operated-to-failure.