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IntroductionIntroduction to Life Cycle Cost

Objectives of Maintenance andMaintenance CostMaintenance DefinitionHow to get unplanned repair jobs plannedMaintenance Procedures

Failure DevelopmentTotal Productivity MaintenanceMaintenance Management Systems

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Modern maintenance management is not torepair broken equipment rapidly. Modernmaintenance management is to keep theequipment running at high capacity andproduce quality products at lowest costpossible.

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Maintenance, then and nowMany years ago, the manufacturing and productionwork was done with relatively simple technical

equipment and the involvement of more manpower.Maintenance was of course simple and impact tocertain extent to the function of machines.During the industrialization, production equipmenthas been more developed. In connection with the high

technical development the impact of productivity andquality has moved from man to machine.The importance of maintenance has considerablyincreased.

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There are many reasons why maintenance is becomingmore and more important. In developing countries , wheremany old machines are operating, the spare part problem

are arising. Some times it is difficult to find spare partsfor equipment and if it is possible to find them, they areusually very expensive and must be paid on foreigncurrency.

Due to long lead times of supply of spares, it is commonthat the spare part inventory is growing bigger than

necessary. A very essential part in maintenancemanagement is developing countries to reduce the needof spare parts, as well as to maintain the minimum level ofshock to save foreign currency, but still keeping theproductivity high.

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Maintenance has to be taken into consideration in very early stage

of work of procuring new equipment to ensure a good and cheapoperation.High quality equipment will give high reliability and maintainabilitywhich secure high productivity and equipment efficiency.The lifetime of the equipment can be spilt up in six phases1.Idea

2.Specification3.Design4.Procurement(Manufacturing)5.Operation6.Windup

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Bath Tub CurveThe bath tub curve describes the cost of equipment over itslifespan. From commissioning to winding up.

Cost

100% LifeTime

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LCC Life Cycle Cost is commonly

understood to be the customerstotal cost and other sacrifice duringthe actual life time of the product.

Hence LCC includes the acquisitioncost as well as all future costs foroperation and support of the product

until it is finally discard.

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Comparison of alternative products.

Improvements of products.

Adaptation of the maintenance and supportorganization.

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Objectives of MaintenanceDuring the years the maintenance function has not beenseen as a condition for production output. The previousapproach has been that maintenance is the necessary evil,one among the cost generators in the organization. Veryoften the maintenance strategy in plants has been toreduce the maintenance cost as much as possible withoutthinking of the consequences.Objective of the maintenance is , as priority one , to create

an availability performance which is suitable for productiondemands in the organization. No mechanized/atomizedcompany has yet succeeded to produce with stoppedequipment. Production buy availability performance frommaintenance.

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1.Keep up the planned availability

performance

2.At the lowest cost

Above allWithin the safety prescriptions

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All enterprises and organizations are interested inlowering maintenance costs. A very commondelusion is that

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MAINTENANCE WICH IS NOT CARRIED OUT,WILL COST EVEN MORE THAN MONEY !!!!!!

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There are two ways of managing the maintenance co

Cost or ResultControlled

Maintenance

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The cost controlled maintenance is not considered as modernmaintenance management, The reason why maintenance has beentreated as a cost controlled activity, Is often that engineers andtechnical staff have had some dilemma to measure the results ofinvestments in maintenance in total economical terms. It is simple

to find the direct cost for maintenance but it could be difficult tosee the results. The upper priority in the objectives of maintenance is to keepup planned availability performance at the lowest cost possible .This means that the long term results are important. Themaintenance cost must be put in relationship with overall results

achieved by maintenance in production facility.

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PRODUCTIONLOSSES

LOSTMARKET

WORKENVIORME

NT

CAPACITYLOSSES

ENERGYLOSSES

QUALITYLOSSES

CAPITALCOSTS

INCREASED

INVESTMENT

MAINTENANCE

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The maintenance cost can be split up in two differentcategories.

Direct maintenance costs -

Indirect maintenance costs -

The costs are directlyrelated to theperformance of themaintenance worksLosses due tomaintenance

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Direct maintenance costsWages & Salaries Material Costs Administration Costs Costs for training Spare parts costs Contracted work forces Modification Costs

Indirect CostsLoss of revenue or other losses as a result ofinterruption to production as a result ofmaintenance.

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Many times there are needs to measure the maintenance efficiency.However, maintenance can not be measured by the cost it creates.There must be an connection to the production out put some way. It is

naturally impossible to determine anything about the size of the directcosts. One method to control the direct maintenance is to use the PM-factor.P stands for prime product produce and M stands formaintenance cost. When using the PM-factor, the result of themaintenance impact on the production is measured. How manyproducts are produced per a 1000 units of maintenance money.

PM Factor = X

Prime Production

Maintenance Cost

1000

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AVAILABILITY PERFORMANCE

The ability of equipment to function properly,Despite occurrence of failures, disturbances and

Limitations in the maintenance resources.

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Availability performance can be divided into tree parts:

Reliability Performance

Maintenance Support Performance

Maintainability Performance

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The ability of an item, under statedConditions of use, to perform a

requiredFunction under stated conditions for

astated period of time.

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The ability of a maintenanceorganization,

Under stated condition, to provideupon

Demand the resources required toMaintain an equipment.

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The ability of an equipment, understarted

conditions of use, To be retained orrestored to state in which it can

perform arequired function, when maintenance is

performed under stated conditions andusing stated procedure and resources.

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In order to set up maintenance strategy for an enterprise, it isnecessary for every body in a company to understand themaintenance concept and speak the same language.

MAINTENANCE

The term maintenance covers allActivities undertaken to keep equipment in a

Particular condition or returnIt to such condition

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The term maintenance consists ofthree main parts

Corrective maintenance

Preventive maintenance

Improvement maintenance

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CORRECTIVE MAINTENANCE(CM)

Corrective maintenance covers allMaintenance which is carried out inOrder to correct (repair) a fault in

equipment

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WHAT IS FALIURE ?

Digress of demands of a certainquality

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Planned & unplanned corrective maintenanceCorrective maintenance is divided in

Break Down

Emergency RepairsUrgent

Not possible toControl

You are controlledby the equipment

PlannedMaintenance

Prepared ProperlyPossible to ControlYou control the

Equipment

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PREVENTIVE MAINTERANCE(PM)

Preventive maintenance covers all

Programmed maintenance which iscarried out in order to prevent theOccurrence of failures before they

Develop to a breakdown orInterruption in production.

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reventive Maintenance is Divided In

PREVENTIVE

MAINTENANCE

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ndirect MaintenanceINDIRECT

PM

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IMPROVEMENT MAINTENANCE (IM)Improvement maintenance is used

When to modify the equipment so theCondition improves. Improvement

Maintenance includes activities whichare carried out once. The objectives of

improvement maintenance are toDesign out the failure i.e. the failure

Will never occur again or extend thelife time of parts.

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One of the objectives of the maintenance job is to get themplannedThis gives increased availability performance and lower

direct maintenance costs and a lot of other advantages. Theload on the maintenance department will for instance belower and the quality of the jobs higher.Use of condition monitoring

Through condition monitoring the failure development and

it is therefore possible to plane the forthcoming jobs beforea break down occurs. By condition monitoring the unplannedjobs are transferred to planned job.

Planned maintenance resulting in lower costs formaintenance and lesser down time.

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Preventive Maintenance-Reduce number of break downs & urgent repairs-More planning and control of corrective maintenance

Result-Increased availability performance & efficiency

-Decreased cost of maintenance

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lts in the correct maintenance work is carrie

At the right time In the right way By the right professional With the right spare parts

Real maintenance management is impossiblewithout condition based preventive maintenance

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When a maintenance strategy is going to beformulated, there are many maintenanceprocedures that could be chosen, Fromsophisticated procedures to low level procedures.

Operate to break down (unplanned correctivemaintenance), O.T.B.DFixed-time maintenance, F.T.M

Condition-based maintenance, C.B.MDesign out maintenance, D.O.MLife-time extension, L.T.ERedundancy, RED

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INDIVIDUAL LIFE TIME

Machines, spare parts, all types ofequipment, have their own individuallifetime. The individual life time is differentfrom part to part and is influenced by thequality of the product but also by other

outside factors such as environment,handling etc.Some failures are occurring after a certain,expected time, and can almost be predicted.

Some failures are occurring completely

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Non-Predictable Predictable

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Failure Developing time(FDT)Some failures either they are random or regular, havelonger or shorter failure development time. The failure

development time is the deterioration time from themoment condition departs from the normal conditionuntil the moment of break down occurs.

Failures with failure development time is easier tohandle than the failures without failure developmenttime.

Shorter FDT Continuous on line condition

monitoring has to be applied

Longer FDT Off-line condition monitoring has tobe applied

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Total Productivity Maintenance (TPM) TPM is a way of organizing maintenance tosupport productivity & quality through increasedequipment efficiency and to reduce costs.TPM concept means that all employees work insmall groups to maximize the improvement of

equipment efficiency.Operators are working independently with allmaintenance activities of their own equipment and

have also the total responsibility of operation andmaintenance.

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Fundamental Goals of TPM

Increased productivity and qualityZero defectsReduced cost of maintenance and producti

Increased motivation among all employeesZero accidentShorter lead timeZero unplanned stops

Development of staff through trainingImprovement of work environment

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Incentives for MMS or CMMS (ruleof thumb)

Reduction on MDT

about 20%

Increased machine life

about 20 %

Saving on labour and spares 10 20%

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General of maintenance systemsThe maintenance function must also have necessary aids to manage themaintenance activities to coop up to the main target of the enterprise.

Maintenance management means a better control of the maintenanceorganization and the related area. To properly control the maintenanceof a facility, information is required to analyze what is occurring.

To be able to manage the maintenance activities in the right way, amaintenance management system is necessary. The system can be

either manual or computerized. The main purpose of a maintenancemanagement system is in operation and works properly.

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Th b i f i f i

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The basic function of a maintenancemanagement system can be :

1. Preventive maintenance2. Plant and unit record(Equipment)3. Inventory and spare parts control system,Purchasing system4.Document record5.Planning system for maintenance and workorder routines

6.Technical/economic analysis of plant history,maintenance and machine availability

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