A Comprehensive Guide to Maintenance Management
DEFINITIONS OF MAINTENANCE
Maintenance is the process organizations use to effectively care for their facilities and avoid potential pitfalls.
Slack
Basic facility maintenance aims to sustain optimal operating conditions as intended in their design and restore them to such conditions if compromised.
Petronius Martins
• Maintenance involves actions taken to preserve or reinstate an asset’s desired state or ensure a specific service level.
Ariza
• The maintenance function encompasses actions aimed at preserving or restoring an asset’s operational state.
Leibel
CHALLENGES OF MAINTENANCE
- Productivity
- Reliability
- Cost
- Safety
- Environment
- People Development
MISSION, VISION, AND OBJECTIVES OF MAINTENANCE
Mission of Maintenance
Ensure the reliability and availability of active systems to meet specified capacity requirements.
Vision of Maintenance
Evolve into a center of excellence for strategic and proactive maintenance of active systems. This involves accurate diagnoses and reliable vital function monitoring to maintain operations within established physical parameters.
Goal of Maintenance
Establish a structured maintenance organization within the industry to ensure an average asset availability of 92% +/- 2%.
OBJECTIVES OF MODERN MAINTENANCE MANAGEMENT
- Maximize equipment and facility availability while optimizing cost, ensuring high quality, and prioritizing safety and environmental protection.
- Optimize spare part inventory levels.
- Support the acquisition of appropriate logistics for materials, parts, and services.
- Maintain comprehensive equipment maintenance records.
- Continuously identify and recommend cost reduction strategies, such as efficient energy use, equipment modernization or replacement, and overall cost optimization.
- Maintain awareness of the company’s maintenance costs and overheads, particularly those associated with production downtime.
OBJECTIVES OF MAINTENANCE
Develop and effectively utilize available resources to preserve the physical integrity of units, ensuring safe and continuous production at the lowest possible cost. This aims to:
- Improve safety
- Increase reliability
- Enhance quality and productivity
- Reduce operating costs
- Extend asset lifespan
CLIENT PERSPECTIVES ON MAINTENANCE
- Asset Owners: Seek a satisfactory financial return on investment from their assets.
- Active Users: Expect consistent asset performance according to established standards.
- Society: Demands asset reliability to prevent environmental hazards in their area of installation.
MAINTENANCE MANAGEMENT
- Strategic alignment with a focus on maintenance.
- Commitment to business results by:
- Ensuring continuity of supply
- Ensuring product quality
- Prioritizing reliability and availability
- Optimizing costs
PREVENTIVE MAINTENANCE
Preventive maintenance involves scheduled actions based on predetermined criteria to minimize the likelihood of asset failure or service degradation.
MAINTENANCE POLICY
- Robust design
- Maintainability
- Preventive attitude
- Operator training
- Strategic spare parts inventory
- Maintenance and contingency planning
- Equipment redundancy
- Increased number of machines with low utilization
TYPES OF MAINTENANCE
- Systematic Maintenance
- Preventive Maintenance
- Predictive Maintenance
- Improvement Maintenance
- Corrective Maintenance
- Total Productive Maintenance (TPM)
CORRECTIVE MAINTENANCE
Corrective maintenance aims to rectify, restore, and reinstate the productive capacity of equipment or facilities experiencing reduced or ceased functionality.
Typically reactive, occurring only after a problem arises. It is implemented post-failure.
SYSTEMATIC MAINTENANCE
This type of maintenance follows a predetermined schedule (time, mileage) and is often automated through a computerized maintenance management system (CMMS). It involves a detailed plan with step-by-step maintenance activities, resource allocation, and estimated labor hours. Monitoring the accuracy and effectiveness of these maintenance plans is crucial.
PREVENTIVE MAINTENANCE
Preventive maintenance involves a series of tasks, such as part replacements, oil changes, lubrication, cleaning, and more, performed according to a predefined schedule. It is initiated based on inspector recommendations or wear measurements, requiring strict discipline.
Proactive: Aims to prevent potential corrective maintenance.
BENEFITS OF PREVENTIVE MAINTENANCE
- Extended equipment lifespan
- Cost reduction, even in the short term
- Minimized production downtime
- Cultivates a preventive mindset within the company
- Scheduled during convenient periods
- Enhanced product quality
PREDICTIVE MAINTENANCE
Predictive maintenance focuses on monitoring specific parameters and conditions of equipment and facilities to anticipate and identify potential issues before they escalate. It relies on analyzing deterioration symptom trends.
Predictive maintenance often involves specialized technology and is commonly outsourced. The key elements are trending and monitoring.
IMPROVEMENT MAINTENANCE
This type of maintenance focuses on enhancing reliability and maintainability. It emphasizes the active participation of maintenance personnel in continuously improving designs, suggesting modifications, and implementing new techniques and materials.
Examples: Suggestion schemes, Quality Control Circles (QCCs), Kaizen events.
TOTAL PRODUCTIVE MAINTENANCE (TPM)
TPM is a management philosophy and organizational behavior approach that extends beyond maintenance to encompass all aspects directly related to the production process.
LOSSES TO BE ADDRESSED
- Breakdowns
- Setup time
- Minor stoppages
- Speed losses
- Quality defects
- Startup losses
HOW TO COMBAT LOSSES
- Capacity
- Maintenance planning
- Best practices implementation
- Standardization
- Technology adoption