Unit of competence
Determine Maintenance Strategy
Level IV
Lo1: Identify and analyze maintenance needs
Answer the following Questions from your
previous knowledge:
• How can you define the term Maintenance?
• What are the purposes of Maintenance?
• What types of maintenance you knew?
• Have you ever used any maintenance strategy to
solve problems
Lo1: Identify and analyze maintenance needs
INTRODUCTION
The definition of maintenance
The definition of maintenance often stated
maintenance as an activity carried out for any
equipment to ensure its reliability to perform
its functions.
Maintenance to most people is any activity
carried out on an asset in order to ensure that
the asset continues to perform its intended
functions, or to repair any equipment that has
failed, or to keep the equipment running, or to
restore to its favorable operating condition.
Lo1: Identify and analyze maintenance needs
Continued…
• Over the years, many new strategies has
been implemented as a maintenance
strategies which is intended to overcome
the problems which is related to
equipment breakdown.
• Maintenance is the combination of all
technical and associated administrative
actions intended to retain an item in, or
restore it to, a state in which it can
perform its required function.
Lo1: Identify and analyze maintenance needs
Continued…
• Many companies are seeking to gain
competitive advantage with respect to cost,
quality, service and on-time deliveries.
• The effect of maintenance on these
variables has prompted increased attention
to the maintenance area as an integral part
of productivity improvement.
• Maintenance is rapidly evolving into a major
contributor to the performance and
profitability of manufacturing systems.
Lo1: Identify and analyze maintenance needs
What is a maintenance strategy?
• Maintenance Strategy is a long-term plan,
covering all aspects of maintenance
management which sets the direction for
maintenance management, and contains
firm action plans for achieving a desired
future state for the maintenance function.
• A Maintenance Strategy brings all current
maintenance practices and operations
together with current industry best
practice.
Lo1: Identify and analyze maintenance needs
Goals of maintenance strategy:
Improve service provision to operations i.e.
reduce breakdowns and improve productivity
Consistently provide parts for planned
maintenance and breakdowns with the lowest
spares holding value
Improve communication between engineering
and other business functions
To ensure engineering is focused on business
objectives
Enable engineering to take a lead in business
development
Lo1: Identify and analyze maintenance needs
Types of Maintenance Strategies
[Link] MAINTENANCE
[Link] MAINTENANCE
[Link] MAINTENANCE
[Link] PRODUCTIVE MAINTENANCE
[Link]-CENTERED MAINTENANCE
Lo1: Identify and analyze maintenance needs
1. REACTIVE /CORRECTIVE MAINTENANCE
It is only performed after a system or component has
failed.
Basically, it is an attempt to restore the system/ product to
a specified condition.
It is the “default” maintenance strategy for many
companies because they will wait until they have a
problem with a computer system.
It involves all unscheduled actions performed as a result of
system or product failure.
The variety of activities within this level are (1) failure
identification, (2) localization and isolation, (3) disassembly,
(4) item removal and replacement or repair in place, (5)
reassembly, and (6) checkout and condition verification.
This is an extremely unreliable process and is not the best
way to maximize the useful life span of one's assets.
Because of its unpredictable nature it can easily cause
disruptions to the production process.
Lo1: Identify and analyze maintenance needs
2. SCHEDULED MAINTENANCE
Scheduled maintenance can be considered a part of
preventive maintenance known as fixed-time
maintenance (FTM).
It is simply planned preventative maintenance.
The scheduled maintenance may take place too
soon, while the machine still operates well (15-20
percent of all components fail after a predictable
time), or it may come too late if the machine fails
before the scheduled maintenance time.
This is much like an oil change on an automobile that
takes place every three months or 3,000 miles.
Lo1: Identify and analyze maintenance needs
2. PREDICTIVE MAINTENANCE
When we are given signs that something might fail soon, we replace
the item. In this case, we have performed predictive maintenance.
Predictive maintenance involves performing maintenance on a
machine in advance of the time a failure would occur if the
maintenance were not performed.
Of course, this means that one must calculate when a machine is
predicted to fail.
In order to do this, the firm must collect data on variables that can be
used to indicate an impending failure (vibration, temperature, sound,
color, etc.). This data is then analyzed to approximate when a failure
will occur and maintenance is then scheduled to take place prior to this
time.
By seeking the correct level of maintenance required, unplanned
downtime is minimized.
For example, if a hard drive in a 4-year-old PC begins to make an odd
noise or speeds up and slows down while running, we replace the drive
before it has a chance to fail.
Lo1: Identify and analyze maintenance needs
3. PREVENTIVE MAINTENANCE
Preventive maintenance is updating or replacing a system,
component or application before any signs of failure appear.
Preventive maintenance encompasses activities, including
periodic inspections ,adjustments, replacement, and basic
cleanliness, that prevent machine breakdowns.
Preventive activities are primarily condition based. The condition
of a component, measured when the equipment is operating,
governs planned/scheduled maintenance.
Let’s say the PC in the above hard drive failure example has a
practical life of 3 years. So, we replace the PC as it becomes 3
years old, even before it shows any signs of component failure,
also mitigating downtime and preventing productivity loss due to
aging hardware. A much more common example is when we
update your security software with the latest releases from the
developer in an effort to prevent a harmful attack on your
system. Some preventative maintenance is required under
Massachusetts information protection laws.
Lo1: Identify and analyze maintenance needs
Benefits of preventive maintenance
• Safety. Machinery that is not well-maintained can become a safety hazard.
Preventive maintenance increases the margin of safety by keeping equipment in
top running condition.
• Lower cost. A modern and cost-effective approach to preventive maintenance
shows that there is no maintenance cost optimum. However, maintenance costs
will decrease as the costs for production losses decreases. Obviously, no
preventive maintenance action is performed unless it is less costly that the
resulting failure.
• Reduction in failures and breakdowns. Preventive maintenance aims at reducing
or eliminating unplanned downtime, thereby increasing machine efficiency.
Downtime is also reduced when the preventive maintenance process gives
maintenance personnel sufficient warning so repairs can be scheduled during
normal outages.
• Extension of equipment life. Obviously, equipment that is cared for will last
longer than equipment that is abused and neglected.
Lo1: Identify and analyze maintenance needs
Continued…
• Improved trade-in/resale value of equipment. If the equipment is to be sold or traded in, a
preventive maintenance program will help keep the machine in the best possible condition, thereby
maximizing its used value.
• Increased equipment reliability. By performing preventive maintenance on equipment, a firm
begins to build reliability into the equipment by removing routine and avoidable breakdowns.
• Increased plant productivity. Productivity is enhanced by the decrease in unexpected machine
breakdown. Also, forecast shutdown time can allow the firm to utilize alternate routings and
scheduling alternatives that will minimize the negative effect of downtime.
• Fewer surprises. Preventive maintenance enables users to avoid the unexpected. Preventive
maintenance does not guarantee elimination of all unexpected downtime, but empirically it has
proven to eliminate most of it caused by mechanical failure.
• Reduced cycle time. If process equipment is incapable of running the product, then the time it takes
to move the product through the factory will suffer. Taninecz found, from an Industry Week survey,
that there is a strong correlation between preventive maintenance and cycle-time reductions as
well as near-perfect on-time delivery rates. Also, approximately 35 percent of the surveyed plants
who widely adopted preventive maintenance achieved on-time delivery rates of 98 percent,
compared to only 19.5 percent for non-adopters.
• Increased service level for the customer and reduction in the number of defective parts. These
have a positive direct effect on stock-outs, backlog, and delivery time to the customer.
• Reduced overall maintenance. By not allowing machinery to fall into a state of disrepair, overall
maintenance requirements are greatly decreased.
Lo1: Identify and analyze maintenance needs
4. TOTAL PRODUCTIVE MAINTENANCE
• Total productive maintenance (TPM) is preventive maintenance
plus continuing efforts to adapt, modify, and refine equipment
to increase flexibility, reduce material handling, and promote
continuous flows.
• It is operator-oriented maintenance with the involvement of all
qualified employees in all maintenance activities.
• TPM has been described as preventive maintenance with these
three factors added: (1) involving machine operators in
preliminary maintenance activities by encouraging them to keep
machines clean and well lubricated; (2) encouraging operators
to report indications of initial distress to the maintenance
department; and (3) establishing a maintenance education and
training program.
Lo1: Identify and analyze maintenance needs
Beneficial results of TPM include:
• Overall equipment effectiveness and
overall efficiency are maximized.
• Operators improve their job skills.
• Capacity is maximized.
• Costs are minimized.
• Product quality is improved.
• Improved safety.
[Link]-CENTERED MAINTENANCE
• It has been assumed that preventive maintenance programs help to ensure reliability and safety of
equipment and machinery. However, tests performed by airlines in the mid-1960s showed that scheduled
overhaul of complex equipment had little or no positive effect on the reliability of the equipment in
service. These tests revealed the need for a new concept of preventive maintenance, which later became
known as reliability-centered maintenance (RCM).
• The concept of RCM is rooted in a 1968 working paper prepared by the Boeing 747 Maintenance Steering
Group. A refined version appeared in 1970. Continued studies at the Department of Defense led to the
1986 publication of the "Reliability Centered Maintenance Requirements for Naval Aircraft, Weapons
Systems and Support Equipment," a set of maintenance standards and procedures that certain military
maintenance personnel were expected to follow. The RCM methodology was further developed and found
application not only in the military and aviation, but also in the energy, manufacturing, foundry, and
transport industries.
• According to Bulmer, the RCM process can be considered as three separate but associated analyses:
failure mode and effects analysis, consequence analysis, and task analysis. These analyses consider the
specific characteristics and consequences of a failure and attempt to arrive at the optimal solution based
on this information.
Self check question on lo1
Q1. One of the following is not true about
definition of maintenance ?
A. It is an activity carried out for any equipment
to ensure its reliability to perform its functions.
B. It is any activity carried out on an asset in order
to ensure that the asset continues to perform
its intended functions.
C. It is only activity carried out to repair any
equipment that has failed.
D. It is the combination of all technical and
associated administrative actions intended to
retain an item to a state in which it can
perform its required function.
Self check question on lo1
Q2. What is Maintenance Strategy?
A. It is a long-term plan, covering all aspects of
maintenance management for achieving a desired
future state for the maintenance function.
B. A good maintenance strategy will reduce
breakdowns and improve firm productivity
C. It is a document that shows what item will be
repaired or replace
D. It is specifically design for preventive maintenance.
E. All of the above
F. None of the above
Self check question on lo1
Q3. Select True statement about REACTIVE
MAINTENANCE ?
[Link] is only performed after a system or
component has failed.
[Link] is an attempt to restore the system/ product
to a specified condition.
[Link] is the “default” maintenance strategy for
many companies.
[Link] involves all unscheduled actions performed as
a result of system or product failure.
E.A and B
[Link] of the above
Q4. When we are given signs that something
might fail soon, we replace the item. In this
case, we have performed _______
A. REACTIVE MAINTENANCE
B. SCHEDULED MAINTENANCE
C. PREDICTIVE MAINTENANCE
D. PROACTIVE MAINTENANCE
E. A AND B
Self check question on lo1
Matching
A.
1. Reactive/Corrective Maintenance
2. Scheduled Maintenance
3. Preventive Maintenance
4. Predictive Maintenance
B
A. Replacing a new Power Supply to the computer due to sudden
power supply failure.
B. Cleaning the computer every 2 months.
C. Secure lose cables
D. Changing the hard drive of the computer due sudden failure.
E. Reinstalling the operating system of the laptop due improper
installation .
