Chapter 9

Maintenance Planning

By : Bahredin A.

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 Maintenance Planning
Maintenance plan is needed to:
 lay down a rational basis for formulating a
program 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 program of the
plant.
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 Production-maintenance interrelation

PRODUCTION PREVENTIVE CORRECTIVE

PROGRAM MAINTENANCE MAINTENANCE
PLAN GUIDELINES

WORKLOAD WORKLOAD

MAINTENANCE
ORGANIZATION

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 Reasons for introducing a maintenance
planning

1) Proper maintenance planning

 Protects investment on machinery, plant and
buildings through adequate
maintenance,
 There by maximizing plant utilization with
minimum downtime and elongating the useful
life of equipment.

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2) Maintenance planning
 minimizes waste of spares and materials;
 ensures proper use of tools; and
 maximizes labor utilization.
Thus, enables good control of maintenance costs.
3) Good maintenance planning
 ensures right distribution of technical
information; and
 can help in establishing proper safety system.
4) Good maintenance planning
 facilitates plant control; and
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 expedites evaluation of plant performance.
 Plant subdivision according to responsibility

PLANT

Higher management
responsibility for
repair/replacement
UNITS

Maintenance
ITEMS management
responsibility for
repair/replacement

COMPONENTS

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Fig. 10.2 Subdivisions of a complex plant 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.

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Proper maintenance planning has some benefits, even

in the simpler plants. These benefits are obtained as:

 reduction in downtime,
 efficient and optimal resource utilization,
 prolonged machine life, and
 good maintenance cost control.

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 Maintenance Policies
The major maintenance policies which can be classified

as corrective and preventive are the following:

i) Fixed time maintenance
ii) Condition-based maintenance
iii) Operate to failure
iv) Opportunity maintenance
v) Design-out maintenance
vi) Total Productive Maintenance
vii) Contract maintenance

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 i) Fixed-time maintenance: (repair prior to failure)

This policy is effective where

 the failure of the item is clearly time dependent, and

 the total costs of such replacement are substantially less than

those of failure replacement-repair.

The item is expected to wear-out within the life of unit.

Difficulty of collecting statistical data should be seriously

considered in adopting this policy.

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ii) Condition-based maintenance

Condition performance monitoring techniques which

are costly in time and instrumentation form the basis

for condition-based maintenance.
The proper time for performing preventive
maintenance is determined by monitoring
condition/performance provided that some parameters
that can be monitored are isolated.

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iii) Operate-to-failure

 In adopting this policy, no predetermined action is taken to

prevent failure.
 Corrective maintenance arises not only when an item fails but

also when indicated by condition-based criteria.

 The basic task is establishing the most economic way of

restoring a unit to an acceptable condition.

 Cost of unavailability, time of repair with that of replacement

(and source of cost) influence the repair-replace choice.

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iv) Opportunity maintenance

 This term opportunity maintenance is used for maintenance

actions directed at items other than those that are the primary
cause of the repair.

 This policy is most appropriate for complex-replaceable or

continuously operating items of high shut-down or unavailability

costs.

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 v) Design-out maintenance

 Design-out maintenance aims at minimizing and eliminating

the causes of maintenance. This requires engineering action

rather than maintenance action.

 This policy is for areas of high maintenance costs which exist

because of poor design or equipment usage outside its design

specifications.

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vi) 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;
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 operators maintain the equipment they use.
 Aims of Total Productive Maintenance
The main aim of total productive maintenance is to

maximize the effectiveness of man-machine systems by

eliminating three types of losses.
1. Downtime losses caused by unexpected breakdowns;
2. Speed losses due to idling and minor stoppages which
arise from temporary stoppages;
3. Defect losses arising from rejects, defects and reworks.

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 vii) 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
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equipment.
 Determination of a 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
 Complex replaceable items
 Non-replaceable items

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 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.

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  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, etc.

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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.

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  An example is shown in the figure below for the selection of maintenance
policy for complex plant items.
EFFECTIVE
POLICY

Action taken based on

Detection of failure All four
Expensive
Age-related
failure pattern
Detection of failure All four
Expensive

COST and SAFETY

Complex
replaceable
items Design-out
Low MTTF Condition-based
Operate-to-failure
Random

requirements
failure pattern
High MTTF Operate-to-failure
Condition-based

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 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.

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 Can reduction in failure YES
be detected on line? List actions

NO

Can reduction in failure YES

be detected at List actions
maintenance base?

NO
Identify cause
YES
Does failure affect and
safety? List actions

NO

Does item have a YES

List actions
hidden function?

NO

Is there an adverse YES

relationship between List actions
age and reliability?

NO

No Preventive Maintenance action

will be effective, operate to failure
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  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.

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 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

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 Thank you
If you have any questions ???

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