Maintenance and installation of Machinery

MEng 5251

2024 Academic year

Semester I

Chapter One Introduction

1
 Chapter one - outlines
1.1 Definition of Maintenance
1.2 Trends in the Evolution of Maintenance
1.3 The Challenge of Maintenance
1.4 Maintenance Management
1.5 Function of Maintenance Work
1.6 Classification of Maintenance
1.7 Maintenance Objectives
1.8 Maintenance Planning, Scheduling and
2
Control
 Maintenance Definition

British Standard Glossary of terms defined

maintenance as:

The combination of all technical and administrative

actions, including supervision actions, intended to
retain an item in, or restore it to, a state in which it
can perform a required function.
Maintenance Definition

Maintenance is a set of organised activities that are

carried out in order to keep an item/a component/ a
machine/a process /a plant /a system, etc in its best
operational condition with minimum cost acquired.
 Maintenance Engineering
It is the discipline and profession of applying
engineering concepts to the optimization of
equipment, procedures, and departmental budgets
to achieve better maintainability, reliability, and
availability of equipment.
It is the occupation that uses engineering theories
and practices to plan and implement routine
maintenance of equipment and machinery.

5
 Maintenance engineers
Are often required to have knowledge of many
types of equipment and machinery.
A person working in the field of maintenance
engineering must have in-depth knowledge of or
experience in basic equipment operation, logistics,
probability, and statistics.
Experience in the operation and maintenance of
machinery specific to a company's particular
business is also frequently required.

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 Skills needed by Maintenance engineering
positions
Excellent interpersonal communication
Participatory management skills.
Planning and implementing routine and preventive
maintenance programs.
Regular monitoring of equipment to visually
detect faults which impends equipment or
production failures before they occur.

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 Q) Why Maintenance activity is done?
Maintenance activity is the systematic and
scientific preservation of equipment for:
 Prolonging(extending) the life of the
equipment,
 Assuring instant operational readiness,
 Optimal availability for production at all times,
and
 Making sure that safety of man and machine is
at no time jeopardized.
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 1.2 Maintenance History

1. In the period of pre-World War II, people thought of

maintenance as an added cost to the plant which did
not increase the value of finished product.

Therefore, the maintenance at that era was

restricted to fix the unit/asset/ when it breaks
because it was the cheapest alternative
 Maintenance History

2. During and after World War II at the time when the

advances of engineering and scientific technology
developed, people developed other types of
maintenance, which were much cheaper such as
preventive maintenance.

In addition, people in this era classified

maintenance as a function of the production system.
 Maintenance History

3. Nowadays, increased awareness of such issues as

environment, safety, product quality and customer
services makes maintenance one of the most
important functions that contribute to the success of
the industry.
World-class companies are in
continuous need of a very well organised
maintenance programme to compete world-wide.
Maintenance History
Development of
Maintenance

--Recognition of
need to present
equipment failures. -Increased
-Models for awareness of:
preventive -Environment
maintenance -Safety
developed. -Quality
Fix the
equipment -Need for reliable
when it breaks equipment.
-Reduction in costs.
Time
Pre-World War II Post-World War II 1980 Onwards

Figure 1.1 Maintenance History (Adapted From Shenoy, Bhadury 1998)

  First Generation
This covers the period up to the World War II.
During this period:
Industry was not highly mechanized,
Equipment was simple and over designed,
downtime did not matter much,
Prevention of equipment failure did not have
high priority,
Failures were corrected as they occur.
 As a result, there was no systematic maintenance
programing beyond cleaning, servicing and
lubrication.
13
  Second Generation
Things changed dramatically during World War II
Wartime pressures increased the demand for goods of all
kinds while the supply of industrial manpower dropped
sharply.
This led to increase in mechanization.
During this period:
 machines became numerous and more complex
 industry started to depend heavily on these machines
 downtime started to matter
 the idea that equipment failures could and should be
maintained came up.
14
 As a result, the concept of preventive maintenance and
 Third Generation
 Since the mid-seventies, the process of change in
industry has gathered even greater momentum.
 Reliability Centered Maintenance-RCM is rapidly
becoming a cornerstone of the Third Generation, but
this generation can only be viewed in perspective in the
light of the 1st and 2nd Generations, John Moubray
(The Author of -RCM)
 The changes can be classified under the headings of
i. new expectations
ii. new research and
iii. new concepts and new techniques.
15
 During this period:
maximizing equipment life has become
important,
higher plant availability and reliability have
become very important,
greater automation has been effected
quality standards, safety and environmental
consequences matter quite a lot,
cost of maintenance is becoming central

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 New expectations
Figure1. 2 shows how expectations of maintenance
have evolved.
Third Generation

Second Generation
First Generation

Figure1. 2 Growing expectations of maintenance

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 New research
The earliest view of failure(i.e. 1st generation) was
simply that as things got older, they were more likely
to fail.
 A growing awareness of 'infant mortality’ led to
widespread Second Generation belief in the
'bathtub'
Third Generation
curve. research has
revealed that not one or two but six
failure patterns actually occur in
practice.

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 Pattern A (has three failure zones).
It is the well-known bathtub
curve.
It begins with a high incidence of
failure (known as infant mortality)
followed by a constant or gradually
increasing conditional probability
of failure, then by a wear-out zone
Pattern B (has two failure zones).
shows constant or slowly increasing
conditional probability of failure,
ending in a wear-out zone.
Pattern C (has one failure zone).
shows slowly increasing
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conditional probability of failure,
 Pattern D (has two failure zones).
shows low conditional probability
of failure when the item is new or
just out of the shop, then a rapid
increase to a constant level,.
pattern E (has one failure zone)
shows a constant conditional
probability of failure at all ages
(random failure).
Pattern F (has two failure zones).
starts with high infant mortality,
which drops eventually to a
constant or very slowly increasing
conditional probability of failure.
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 New concepts and Techniques
 There has been explosive growth in new
maintenance concepts and techniques.
 Hundreds have been developed over the past
fifteen years, and more are emerging every
 Maintenance
week overhauls and
administrative systems has grown to Third
Generation
include many new developments in
a number of different fields.
Second Generation

First Generation

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 Generally
The new developments in different fields
include:
 decision support tools, such as hazard
studies, failure modes and effects analyses
and expert systems
 new maintenance techniques, such as
condition monitoring.
 designing equipment with a much greater
emphasis on reliability and maintainability
22  a major shift in organizational thinking
 Interim summary
 First generation(two failure patters identified-PATTERN B)
a) constant or gradually increasing conditional probability of failure,
b) wear-out failure
 Second generation
(three failure patters identified-PATTERN A)
a) Infant mortality
b) constant or gradually increasing conditional
probability of failure
c) wear-out failure

 Third generation (six failure patters identified)

 Failure patterns A,B,C,D,E,F
23  The idea of RCM BASES ON this generation(next slide
 Six patterns of failure
• The x-axis represents age, which can be measured in any units
such as calendar time, operating hours, miles, and cycles.
• The y-axis represents the conditional probability of failure.

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Tips: Definition of RCM: Managing the Consequences of
Failure
 Reliability Centred Maintenance: a process used to determine
the maintenance requirements of any physical asset in its
operating context.
 The RCM process involves asking seven questions about the asset or
system under review
1. what are the functions and associated performance standards of the
asset in its present operating context? (Functions and Performance
Standards)
2. in what ways does it fail to fulfil its functions? (Functional Failures)
3. what causes each functional failure? (Failure Modes)
4. what happens when each failure occurs? (Failure Effects)
5. in what way does each failure matter? (Failure Consequences)
6. what can be done to predict or prevent each failure? (Failure
management: proactive action [scheduled restoration, scheduled
25 discard and on-condition maintenance])
 Figure 1.3 Flow of RCM Process

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 1.3 The Challenges of Maintenance
The challenges that modern maintenance
managers face are summarized as follows:
o to select the most appropriate techniques
o to deal with each type of failure process
o in order to fulfil all the expectations of the
owners of the assets, the users of the
assets and of society as a whole
o in the most cost-effective and enduring
fashion
27 o with the active support and co-operation
 1.4 Maintenance Management
It is the direction and organization of resources
in order to control the availability and
performance of an item/a plant/a system to a
specified level.
Resources include: materials, tools,
equipment.
In maintenance management the problem is two-
dimensional:
 Determination of size and nature of the
maintenance work load,
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 Organization and control of labour, spares
 1.5 Function of maintenance work
Earlier the objective of maintenance
function was considered to optimize plant
availability at minimum cost.
Today it is being considered as "Maintenance
affects all aspects of business effectiveness
and risk-safety, environmental integrity,
energy efficiency, product quality and
customer service, not just plant availability
and cost."
29
 The maintenance department influences plant
availability directly through preventive and
corrective maintenance.
The most basic definition
T of availability is
op
Availabili ty 
Top  Tdown

where Top = cumulative time of operation

Tdown= cumulative outage
time(downtime)
Tdown= Down time = repair time +
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delays
 Equipment Time
EQUIPMENT TIME

ACTIVE TIME INACTIVE TIME

UPTIME DOWNTIME

MAINTENANCE MODIFICATION DELAY

PM TIME CM TIME

PROCUREMENT FAULT
PREPARATION CLEANUP
TIME CORRECTION
TIME TIME
TIME

ISOLATION ADJUSTMENT CHECKING LOGGING AND

TIME CALIBERATION TIME RESTORATION
TIME TIME

REPAIR IN REMOVE REMOVE AND REPAIR

PLACE REPLACE-REPAIR WITH A LIKE ITEM

INSPECTION SERVICING REPLACING MINOR OVERHAUL MAJOR OVERHAUL

TIME TIME TIME TIME TIME
(aging units)

Figure 1.4 Equipment Time

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 Equipment Down Time

DOWNTIME

CM PM DELAYS
(Repair Time) (Off-line Time) (Waiting for M)

RESOURCES INFORMATION

MAINTAINABILITY MANAGEMENT ENGINEERING TECHNIQUES

(Logical fault-finding: Diagnostics)

Figure 1.4 Equipment Down Time

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1.6 Types of Maintenance
Unplanned
A. Run to Failure Maintenance (RTF)/Reactive/
Maintenan
B. Preventive Maintenance (PM) ce
C. Corrective Maintenance (CM)
D. Improvement Maintenance (IM)
Planned
Maintenance
E. Predictive Maintenance (PDM)
F. Proactive maintenance(PRM)
Fig 1.5 Types of Maintenance
MAINTENANCE

PLANNED UNPLANNED
MAINTENANCE MAINTENANCE
(PROACTIVE) (REACTIVE)

EMERGENCY BREAKDOWN

PREDECTIVE PREVENTIVE IMPROVEMENT CORRECTIVE

MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE

STATISTICAL CONDITION - DEFERRED REMEDIAL

ENGINEERING DESIGN -
- BASED BASED
SERVICES OUT

Shutdown Maintenance

WINDOW RUNNIN ROUTINE OPPORTU SHUTDOWN SHUTDOWN SHUTDOWN

G -NITY PREVENTIVE IMPROVEMENT CORRECTIVE
 A.Run to Failure Maintenance (RTF)
 The required repair, replacement, or restore action
performed on a machine or a facility after the
occurrence of a failure in order to bring this machine
or facility to at least its minimum acceptable condition.
Q) What do you decide to restore equipment function if
the failed part is no longer manufactured or stocked or
if there is no spare available on hand?
 Run to Failure Maintenance (RTF)
 It is subdivided into two types:
a. Emergency maintenance: it is carried out as fast
as possible in order to bring a failed machine or
facility to a safe and operationally efficient
condition.
b. Breakdown maintenance: performed when
equipment receives maintenance (e.g., repair or
replacement) only when the deterioration of the
equipment’s condition causes a functional failure.
 Performed to fix items that has broken down,
faulted and
malfunctioned-failed to function.
 To understand an asset functional failure, let’s discuss an
asset performance.
 Performance of an item(asset) can be defined in two
ways:
1. What the asset can do: DESIGNED
PERFORMANCE/INHERENT PERFORMANCE/
INITIAL CAPACITY/BUILT-IN CAPABILITY
Forwants
2. What the user example, the primary
the asset function of
to do: DESIRED
the pump is:
PERFORMANCE
'to pump water from tank X to Tank
Y not less than 800 liters/minute'.

 Pumping function could suffer from two functional

failures, as follows:
a) Fails to pump any water at all
(Total failure=zero flow rate, zero
performance)
b) pumps water at less than 800 litres per minute
37 (Partial failure=operating below desird
performance).
 Therefore an asset functional failure is defined
as the incapability of an asset or an equipment
to provide its designed and or desired
performance
Why? standards.

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 Run to Failure Maintenance (RTF)
Disadvantages:
1. Its activities are expensive in terms of both direct
and indirect cost.
2. Using this type of maintenance, the occurrence of a
failure in a component can cause failures in other
components in the same equipment, which leads to
low production availability.
3. It is unpredictable and making budgeting, planning,
and resource levelling(allocating) impossible.
4. The maintenance is unexpected(reactive) and has
unscheduled equipment downtime.
 Run to Failure Maintenance (RTF)
This type of maintenance is useful in the following
situations:
1. The failure of a component in a system is
unpredictable.
2. Its cost of performing maintenance activities is
lower than other types of maintenance.
3. The equipment failure priority is too low in order
to include the activities of preventing it within the
planned maintenance budget.
 B. Preventive Maintenance (PM)
It is a set of activities that are performed on
plant equipment, machinery, and systems
before the occurrence of a failure in order to
protect them and to prevent or eliminate any
degradation in their operating conditions.
 Preventive Maintenance (PM)
 It is good for those machines and facilities
which their failure would cause serious
production losses.
 Its aim is to maintain machines and facilities in
such a condition that breakdowns and emergency
repairs are minimised.
It may be
 Daily maintenance (cleaning, inspection,
oiling and re-tightening)
 Periodic inspection or equipment condition
diagnosis.
 In general, its activities include:
replacements, adjustments, major overhauls,
Preventive Maintenance (PM)
Preventive maintenance is performed based on
restated criteria (pre-set time schedule) after a
set amount of elapsed calendar time or machine
run time, regardless of whether the repair is
needed.
 Preventive Maintenance (PM)
The factors that affect the efficiency of PM:
1. The need for an adequate number of staff in the
maintenance department
2. The right choice of production equipment and
machinery that is suitable for the working
environment and that can tolerate the workload of
this environment.
3. The required staff qualifications and skills, which
can be gained through training.
4. The support and commitment from executive
management to the PM programme.
5. The proper planning and scheduling of PM
 Preventive Maintenance Classification(PM)
Researchers subdivided PM into different
kinds according to the nature of its activities:
a) Routine maintenance which includes those
maintenance activities that are repetitive
and periodic in nature such as lubrication,
cleaning, and small adjustment.
b) Running maintenance which includes those
maintenance activities that are carried out
while the machine or equipment is running
and they represent those activities that are
performed before the actual preventive
maintenance activities take place.
 Preventive Maintenance Classification(PM)
c) Opportunity maintenance which is a set of
maintenance activities that are performed on a
machine or a facility when an unplanned
opportunity of failure exists during the period of
performing planned maintenance activities to other
machines or facilities.
d) Window maintenance which is a set of activities
that are carried out when a machine or equipment is
not required for a definite period of time.
e) Shutdown preventive maintenance, which is a set
of preventive maintenance activities that are carried
 Advantages of PM
1. It is predictable, making budgeting, planning,
and resource levelling(allocating) possible.
2. It prevents most major problems, thus
reducing
forced outages, “reactive maintenance,” and
maintenance costs in general.
3. It satisfies most of maintenance objectives.
4. It assures managers that equipment is being
maintained.
47 5. It is easily understood and justified.
 Disadvantages of PM
1. It is time consuming and resource intensive.
2. It does not consider actual equipment
condition when scheduling or performing
the maintenance.
3. It can cause problems in equipment in
addition to solving them (e.g. damaging
seals, gaskets, stripping threads, etc…).

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 C. Corrective Maintenance (CM)
 In this type, actions such as repair, replacement,
or restore will be carried out after the occurrence
of a failure in order to eliminate the source of this
failure or reduce the frequency of its occurrence.
The maintenance is performed to identify
(troubleshot), isolate, and repair a fault in order
to restore equipment, a machine or a system.
• The maintenance carried out
after recognition of defects and
intended to put an item into a
state in which it can perform a
required function.
 Corrective Maintenance Classification
a. Remedial maintenance, which is a set of
activities that are performed to eliminate the
source of failure without interrupting the
continuity of the production process.

The way to carry out this type of corrective

maintenance is by taking the item to be
corrected out of the production line and
replacing it with reconditioned item or
transferring its workload to its redundancy.
 Corrective Maintenance Classification
b. Deferred maintenance, which is a set of
corrective maintenance activities that are not
immediately initiated after the occurrence of a
failure but are delayed in such a way that will not
affect the production process.
It is the practice of postponing maintenance
activities due to lack of personnel, not enough
parts and equipment, insufficient time, scarce
budget.
c. Shutdown corrective maintenance, which is a
set of corrective maintenance activities that are
performed when the production line is in total
stoppage situation.
 Corrective Maintenance (CM)
 The way to perform corrective maintenance
activities is by conducting four important steps:
1. Fault detection.
2. Fault isolation.
3. Fault elimination.
4. Verification of fault elimination.
 In the fault elimination step several actions could
be taken such as adjusting, aligning, calibrating,
reworking, removing, replacing or renovation.
 Corrective Maintenance (CM)
Prerequisites in order to be carried out CM
maintenance:
1. Accurate identification of problems
origination.
2. Effective planning which depends on the skills
of the planners, the availability of well
developed maintenance database about
standard time to repair, a complete repair
procedures, and the required labour skills,
specific tools, parts and equipment.
3. Proper repair procedures.
4. Adequate time to repair.
5. Verification of repair.
Interim summary-Corrective Maintenance (CM)
 The main objectives of corrective maintenance are
 the maximisation of the effectiveness of all critical
plant systems.
 the elimination of breakdowns,
 the elimination of unnecessary repair, and
 the reduction of the deviations from optimum
operating conditions.
 The difference between Corrective Maintenance(CM)
and Preventive Maintenance(PM) is that for the
corrective maintenance, the failure should occur before
any corrective action is taken.
 Corrective Maintenance(CM) is different from Run
to Failure Maintenance(RTF) in that its activities are
planned and regularly taken out to keep plants, machines
and equipment in optimum operating condition.
 D. Improvement Maintenance (IM)
 It aims at identifying and implementing improvement
actions for reducing or eliminating entirely the need for
maintenance.
 Divided into three types :
1. Design-out maintenance
 Maintenance activities that are used to: eliminate the cause of
maintenance, simplify maintenance tasks, or raise machine
performance from the maintenance point of view by
redesigning those machines and facilities which are
vulnerable to frequent occurrence of failure and their long
term repair or replacement cost is very expensive.
 It is a design oriented curative means aimed at rectifying a
design defect originated from improper method of installation
or poor choice of materials etc.
 Improvement Maintenance (IM)
2. Engineering services activities which includes:
construction and construction modification
removal and installation, and
rearrangement of facilities.
3. Shutdown improvement maintenance, which is a
set of improvement maintenance activities that are
performed while the production line is in a
complete stoppage situation.
 E. Predictive Maintenance (PDM)
It is a set of activities that detect changes in the
physical condition of equipment (by detecting signs
of failure) in order to carry out the appropriate
maintenance work for maximising the service life of
equipment without increasing the risk of failure.
  According to the methods of detecting the
signs of failure, it is classified into two kinds:
1. Condition-based predictive maintenance
2. Statistical-based predictive maintenance

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 Predictive Maintenance (PDM)
1. Condition-based predictive maintenance
depends on continuous or periodic condition
monitoring equipment to detect the signs of
failure.
2. Statistical-based predictive maintenance
depends on statistical data from the
meticulous(careful) recording of the
stoppages of the plant items and components
in order to develop models for predicting
failures.
 Predictive Maintenance (PDM)
 The drawback of predictive maintenance is that it
depends heavily on information and the correct
interpretation of the information.
 Some researchers classified predictive maintenance
as a type of preventive maintenance.
 The main difference between preventive
maintenance and predictive maintenance is that
predictive maintenance uses monitoring the
condition of machines or equipment to determine
the actual mean time to failure whereas preventive
maintenance depends on industrial average life
statistics (based on time intervals).
 F. Proactive Maintenance
That is it strives to identify(monitor) and eliminate
(correct) the root cause of asset failure.
The strategy is designed to extend the useful age of the
equipment to reach the wear-out stage by adaptation a
high mastery level of operating precision.
The infant mortality failure mode is a quality
control issue,
The wear-out failure mode is a maintenance
issue.
The random failure or constant rate mode: is
product reliability issue.

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 Involvement/intervention/ of
Maintenance activities
Maintenance is related to profitability
through:
 equipment output and equipment running
cost.
 time taken for maintenance purposes.
The level of maintenance required and
involvement
“Maintenanceatintervention
the equipment operation
is considered
stage is affected byoffactors
in all phases(stages) at other
Equipment Life –stages
through
Cycle.” which the equipment passes.
62
 Equipment Life – Cycle

OPERATIONAL INVOLVEMENT

MANUFACTURE COMMISSIONING OPERATION

SPECIFICATION DESIGN REPLACEMENT
INSTALLATION
- Conceptualization - Performance - Primary design - Design fault - Wear-out
- Reliabilty - Quality control fault control detection - Obsolescence
- Maintainability - Design fault - Technical - Maintenance
- Support system detection performance test optimization
- Maintainability - Maloperation
avoidance

LEARNING PERIOD

CONTINUAL FEEDBACK

Fig. 1.2 Equipment life-cycle

Figure 1.6 Equipment Life – Cycle

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  Design stage:

 Reliability and maintainability are the important factors which should

be considered properly in relation to performance of equipment,

capital and running costs.
 Installation stage:

 Maintainability is an important factor to be considered during the

installation, for it is here that maintenance problems become clear.

 Commissioning stage:

 This is a stage of technical performance testing and also a stage of

where primary design faults are located and designed out.

 Operational stage:

 The operational stage is a stage of learning where maintenance plays

an important role.
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 1.7 Maintenance Objectives
 The relation between maintenance objectives and
production goals is reflected in the action of keeping
production machines and facilities in the best possible
condition.
 Therefore, maintenance objectives should be
consistent with and subordinate to production goals.
Maintenance purposes, functions and objectives are
inter-related and are overlapping to some extent.
Maintenance Objectives

PLANT

Maximising Production Reduce Breakdowns

M
A
Minimising Energy I Reduce Downtime
Usage N
T
Optimising Useful Life of Improving Equipment
E
Equipment Efficiency
N
Providing Budgetary A Improving Inventory
Control N Control
C
Optimising Resources E Implementing Cost
Utilisation Reduction

Figure 1.7 Maintenance Objectives

 To safeguard investments by minimizing rate
of deterioration and achieving this at optimum
cost through budgeting and controls; maintain
plant equipment, and facilities at an economic
level of repairs at all times, to conserve these
and increase their life-span
To help management in taking decisions on
replacements or new investments and actively
participate in specification preparation,
equipment selection, its erection and
commissioning etc,
67
 Help in implementation of suitable procedures
for procurement, storage and consumption of
spares, tools and consumables etc (inventory
control etc)
Standardization of spares and consumables, in
conformity with plant, national and international
standards and help in adoption of these standards
by all users in the plant
Running of centralized services like steam
generation and distribution, water supply, air
supply and fuel etc.
68 Running of captive workshops for repairs and
 Effect of Poor Maintenance
Inadequate or lack of effective and efficient
maintenance system especially in a manufacturing
enterprise gives rise to several undesirable
consequences.
I. Excessive machine breakdown
II. Frequent emergency maintenance work
III. Shortened life-span of the facility
IV. Poor use of maintenance staff
V. Loss in production output
VI. Inability to meet delivery dates
69 VII. Excessive overtime
 1.8 Maintenance Planning, scheduling and control
Having known fault lists, results of condition
monitoring, and having decided the
type/strategy of maintenance, the next step is
to plan, schedule and control the maintenance
jobs.

70
 1.8.1 Maintenance Planning
It covers the full range of preparation of work order
system(job coding, job prioritization, degree of
autonomy of execution)
 It ensures the necessary materials, tools, parts,
manpower, etc…
It deals with answering two questions:
1. “what” maintenance activities/job are to be done.
2. “how” this maintenance activities/job are to be
done, moreover
 It answers the following supplementary questions:

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a) “Where” the maintenance activities/job are to be
done.
 1.8.2 Maintenance scheduling
Maintenance scheduling: is a function of
coordinating all logistics issue.
Maintenance scheduling deals with answering
two questions:
1. “who” would do the maintenance
activities/job.
2. “when” the maintenance activities/job
would be started and done.

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 Example 1: Sample plan for a small job of changing V-belt of blower X.

73
 1.8.3 Maintenance work control
This is a function of the maintenance organization and
its object is to match men, spares and equipment to
the maintenance work load.
That is it matches Cost Break Down(CBD) with Work
Break Down(WBD) of each maintenance activity.
This function includes:
• location of plant failure,
• determination of the necessary corrective action,
• the setting of priorities,
• coordination and control of resources.
 To accomplish the function: plant condition and
74 maintenance cost has to be controlled.
 1.8.3.1 Plant condition control
This function is required in order to achieve optimum
plant performance in the long term.
The function of plant condition control is to
identify the most important problems,
diagnose causes,
prescribe solutions,
In achieving this functions, the alternative actions
available are:
Modification of preventive maintenanc policy
equipment re-design (especially in the early period
of an equipment life)
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changes in production policy,
 1.8.3.2 Maintenance cost control
The objective of maintenance cost control is to
minimize the sum of costs related to
maintenance activities
 The function of cost control is:
 to identify high cost areas of plant,
to monitor the trend of maintenance
effectiveness,
to provide information for maintenance
decision making
76 to facilitate maintenance budgeting.
 Chapter End!!

Any question

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