You never cease to provide a wealth of knowledge. It is essential to involve employees in the planning of strategy and direction for the organization. Replacing large lube oil quantities is indeed expensive but so is a significant equipment failure, so tread carefully. Thank you for the comment Eyadeh. Good share Erick,at our site we clasify type of maintenance Proactive (PM,Pdm,Sca)maintenance and Reactive maintenance(emergency),PM we implement based on ,by time base equipment recomended,Pdm we implement by critical equipment mapping,Sca we implement by Work request and inspection. Can we say that predictive maintenance is a new type of maintenance appeared with industry 4.0 and not a branch of preventive maintenance? P.O. Inadequate equipment maintenance will impact to safety also, maintenance members and others. Second is about Surveillance / monitoring tasks I’m fully agree with this discussion especially on this current Upstream O&G business situation where cost optimization (reduction?) Very knowledgeable article. Your MPS process outputs directly impact the way Maintenance Department Managers will run the Maintenance Crews, they affect your Materials Management process, and they define how you coordinate the Production Group and your subcontractors. Inspections, vibration rounds, lubrication rounds, … are clearly preventive maintenance, but what if the preventive maintenance (e.g. ( By Reliability ( weibull) Vs Cost) or there is a better way! Please keep your good job and you are already making huge difference. no significant impact on safety or the environment) and preventing failure is either not economical or not possible. It is based on the assumption that the failure is acceptable (i.e. Render better service to operations by performing most important jobs first (as determined by operations) 4. Hi Erik When you implement a Risk Based Maintenance process effectively you should have reduced the total risk of failure across your plant in the most economical way. Start with the basic maintenance management flowchart below and identify the main inputs and outputs required from each box in the flow loop. How you classify your maintenance in your CMMS can help but I would not make this a priority until a lot of other things were in place. Low risk equipment may be maintained at a much lower frequency and possibly with a much smaller scope of work. I have been dealing with a system where they only classify into regular maintenance, non-critical issues and then critical issues. In the real life we have to asses all aspect that contribute to the business success provided with operational and safety excellence. This is highly inefficient and something you should avoid at all cost. This type of maintenance conducted only if the machine stop in the middle of production. The opposite of Planned Maintenance is Unplanned Maintenance which has not properly been prepared and is planned on the plan as the job is done. Corrective maintenance is done after a failure has occurred either as Deferred Corrective Maintenance or as Emergency Maintenance. This distinction is important for understanding, and it has the advantage of being “logical”. would please help me in suitable originations chart for oil company maintenance Section In fact, World Class organisations ensure that less than 2% of their total maintenance is Emergency Maintenance. Some occasions when we found wear parts (the machine is still okay to run). Then for each box draw a high level conceptual flowchart that shows how your operation will deliver those particular inputs and outputs. Have a look at this article: https://roadtoreliability.com/sell-planning-scheduling/. It could be said that performing preventative imposes to perform surveillance or monitoring tasks. long term high cost, equipment efficiency degradation, costly emergency intervention, major accident event, etc.). All you PM’s are proactive in my view and where you have accepted a run to failure strategy I would even consider the resulting CM’s proactive as you have made a deliberate choice to allow that failure to happen (i.e. Provide orderly procedures for pr… For those who have not found the Road To Reliability community please do so. If you've found this article helpful and would like to get your own PDF copy of the article and a supporting presentation that explains the different types of maintenance and when to use them simply click on the link below and leave your details: And frequently asked question is ‘what is breakdown maintenance’ and as it’s not in my explanation I thought I’d just covered it here briefly. Quickly build an EAM system that ensures a lifetime of world class reliability and utmost operating profits from outstandingly reliable operating assets. By determining the work details up front before the actual work takes place, planning allows for the most efficient use of maintenance resources. Hi Erick As far as I am concerned terminology is not important. I do not like talking in terms of PM, CM, PdM etc as it makes the picture blurred. 1. Thanks for sharing this informative and clear work. Oil changing work is too expensive. The maintenance strategies and types you would use for building maintenance would depend on the failure modes you’re looking to manage, plus of course any legislative maintenance requirements. Maintenance work can be hazardous. hi erik. At the top level, I see maintenance being either preventive or corrective: Preventive maintenance can be defined as “an equipment maintenance strategy based on replacing, or restoring, an asset at a fixed interval regardless of its condition. A Maintenance Planning and Scheduling Process needs to be designed. And it is less safe. Size of the market depends upon the sales potential rather than on the geographical areas. This article presents an assessment of the influential factors that space planners and design professionals must consider during the planning and design of office space in corporate facilities, so as to enable staff to perform their tasks as efficiently as possible. These are the 2 types which I am concerned about. If you came to one of our three day Maintenance Planning and Scheduling Training Courses you would learn all that you need to know about maintenance planning and scheduling process design and the maintenance planning and scheduling process contents. As you say, they correspond to a decision, a strategy adopted, or as some books state, an evolution to “reactive” to “proactive”. Another example would be the replacement of a car wheel, that can be performed on a flat (failed) tyre or before the tyre gets too worn. They do not represent a mathematical “partition” of all the maintenance tasks. Building ownership will require them to invest time and effort in the development of the processes they will manage. Just a cent from me. As I already pointed out above Emergency Maintenance is expensive, various sources have suggested that Emergency Maintenance is 3 to 5 times as expensive as ‘normal’ preventive maintenance. You will also be able to select the appropriate supporting technologies now that you know what information needs to be available to each function in the process. This article means to give an overview of the different maintenance types and in what circumstances they should be used. Doing so i also discovered, even if this is odd, that those concepts are not always properly defined in academic books, and even in some standards. It is more expensive, less efficient, and less safe. And non age related failure modes are best managed with some kind of condition assessment so that gives you some indication. Hi Hazim, try turning that question around: what failures may lead to those motors not being available when you need them? attention than in the past when maintenance functions were something of a “Cinderella” activity. Hi Rizaldi, I don’t like to give percentages for PM, CBM and CM ratios as people just take those numbers and forget to think. I am not saying anybody else is doing it in a wrong way. Neither. Read more at Online Maintenance Planning and Scheduling Training Course. The most expensive type of maintenance is Emergency Maintenance because this is the type of maintenance that is so urgent that you drop everything to run off and fix the problem. In general, prevention of a failure is simply a lot cheaper and safer than letting equipment fail. whereas preventive maintenance is maintenance that has been identified to … I have to do better then this. I have to provide them with a complete setup plan for the department on operational level, including all necessary work processes, and recommendations based on best practices and least cost option on organizational, technical and tactical level. Includes call outs for stupid faults. Exact same task. Hi Erik, However, most failure modes do give some sort of warning that they are in the process of occurring or are about to occur. The executive and middle level managers of your company are the ones most in touch with the end customers. documentation of all maintenance work is a key element, and AMTs typically spend as much time updating maintenance logs as they do performing the work. A reactive maintenance environment is not where you want to be. So although a run-to-failure strategy can be a good option, make sure you decide wisely. Examples of Risk-Based Maintenance would be Risk-Based Inspection as applied to static equipment like vessels and piping or even pressure relief valves. Many thanks Sir. The secret to effective project planning and management is staying organized and communicating well with your team and stakeholders. I like to keep things simple and therefore prefer a simple differentiation of it’s either a PM (before failure) or a CM (after failure). So to level the playing field, it is necessary to explain the way in which a few of these terms have been utilized throughout this document to ensure common understanding by all who read it. thank you. running to failure). The subject is very interesting. Hi Moses, there are many KPIs or performance metrics that you can use to manage and improve maintenance. I prefer to keep the planned and unplanned distinction for (corrective) maintenance to identify those maintenance tasks that have not been planned i.e. I have a different view on this. So for example you would use failure finding maintenance to test your building fire and smoke detectors on a regular basis. Thanks for clarifying the types of maintenance tasks. Operations 1. I limit the use of that phrase as for some reason people then jump to the conclusion that another maintenance is not scheduled. Trying to replace these lights before they fail would be a waste of money because we cannot accurately predict when lightbulbs will fail. Still exact same task, same series of steps. Planning is one of the main processes of effective maintenance departments. How to Choose the Right Maintenance Strategy, Add a header to begin generating the table of contents, 9 Types of Maintenance: From Preventive Maintenance to Corrective Maintenance and Everything in Between. If so, send me a more detailed message with a bit more background to your question via the contact page and I’ll do my best to answer. The purpose of Time Based Maintenance is to protect yourself against the failure of known wearing parts which have predictable Mean Time Between Failure (MTBF) i.e. in preventive mode. not sure how that would work with software though. Excellent summary.. This is because this type of maintenance does not go through the full maintenance planning & scheduling process because it's so urgent and it's simply planned on the fly. In the chart of maintenance types I broke ‘corrective maintenance’ into two sub-types: And that was very deliberate because it is so essential that we absolutely minimize the amount of Emergency Maintenance we allow into our organisations. what is a proactive procedure that issued to achieve efficient maintenance activities in a building by minimizing the expenditure and optimizing the value derived. Importance of Planning: Planning is the key to success of an organisation. i want to ask You see, if you adopt run-to-failure for equipment that once it has failed must be restored immediately to have doomed your organisation to a reactive maintenance environment. Easy to read and make it easily understood. It was very informative. Click this link to download the free 299-page Plant and Equipment Wellness PDF book and templates on how to get world class reliable operating assets. Thanks Erik for this clarification. Minimize downtime and interruptions to operations 3. In some way be sure to involve the managers and the supervisors from Maintenance (and occasionally those from Production) in reviewing the proposed MPS process designs. Save my name, email, and website in this browser for the next time I comment. There are on one hand those tasks dedicated on restoring function (greasing the door, changing the wheel), the interventions, and on the other hand those other tasks dedicated to assessing the state or condition of the equipment. Nice Erik, thank you so much, but can you please suggest more topics for my research, I really appreciate your help. BR But when it comes to the Road to Reliability it is a dead end. It is really good reading. For CBM to be effective as a strategy, early intervention is essential. I believe the solution to this is Predictive Maintenance in the form of simple wireless remote monitoring IoT network sensors that monitor your assets on a 24/7 basis that alerts you in real time to any abnormalities it detects preventing costly damages and maximising up-time. The prime objective of good maintenance planning and scheduling is to allow maintenance personnel to prepare and perform the required task in a safe and cost effective manner without encountering time wasting delays.Here are five tips that can make you a more effective Planner/Scheduler. Types of maintencae is well explained by you. Thanks for the detailed description of maintenance. What education should these planners and schedulers need? One famous approach is risk-based management decision. Some same tasks could be performed under corrective or preventive modes. Another common issue with Emergency Maintenance is that often parts and services are expedited to arrive faster and increased costs are incurred to make that happen. 9. Probably a better term could be used, i personally prefer the term “surveillance”. Apart from being the outcome of a deliberate Run to Failure strategy Corrective Maintenance is also the result of unplanned failures which were not avoided through preventive maintenance. So when a corrective maintenance work request is raised it is essential that you prioritise it properly to make sure that where possible you defer the work request and give your team the time to properly plan and schedule the work. Planning is the synthesis of various forecasts—short-term or long-term, special or otherwise. Thanks. As such it is a type of preventive maintenance. In this occasion please allow me to pray for the health of all of you wherever you are. Maintenance practitioners across industry use many maintenance terms to mean different things. Hi Erik, When to use condition-based maintenance. Maintenance and reliability strategic review. How many maintenance planners and schedulers do I need for this department? Any BUISINESS has to maintain product quality and operational effectiveness or it will never compete, therefore the operational running costs have to include a significant amount of Fixed TBM. Outage planning: someone in this new department has to do this. You will also need to explain how Purchasing and Materials Management will function during the planning, scheduling and execution of maintenance work. Time-Based Maintenance refers to replacing or renewing an item to restore its reliability at a fixed time, interval or usage regardless of its condition. 1. Some people get very excited about these definitions and can spend a lot of time on for example disagreeing with what is and what isn’t preventive maintenance. Definition of Manpower Planning: Manpower planning may, be defined as, “the replacement planning which analyse labour turnover, recruitment policy, promotion, development and maintenance of employee programmes and assess … Because it easier to note number of breakdown in one week, we use this for our maintenance priority. in corrective mode, or when the door function is ok, or start to be less easy to slam (goes beyond the “p” point of the p-f curve), i.e. All take data from equipment and equipment not stop, it call Predictive Maintenance/Condition Based Maintenance.And then using data, make trending. cost optimization and minimal production interruption) could easily falling to the “unexpected” very costly compensation (e.g. and wish you success. It gives me a clear picture whether we are doing PM or PdM more. Well we have two components to this People and Computer/Mechanical, both cause issues that trip either designed safeties or move the system out of functional limits unintentionally. This requires an efficient and effective process for data gathering, data analysis, decision making and finally intervention. Scheduled restoration tasks and replacement tasks are examples of preventive maintenance tasks.” 1Ramesh Gulati, Jerry Kahn and Robert Baldwin. It is where observation and experience comes into place in order to perform intervention only when appropriate. For an aircon system you would probably use time-based maintenance to replace filter elements. But it could be misleading in terms of classification of tasks. Hi Wirza, that aligns quite well with what I describe. Starting from weekly, monthly, 3 monthly, 6 monthly, yearly, 2 year, and so on. Thanks a lot for useful and very interesting subject about type of maintenance. Hi Erik, When the parts comes to our site, and when we do the replacement we call it by Corrective Maintenance. Thousands of work-related accidents, resulting in more than three days off work are reported to the Health and Safety Authority each year. The following equations required specific and detailed answer, 1- Can u explain reliability vs PM You should also read the article Maintenance Backlog Management for a summary of what you are trying to accomplish with a maintenance work planning process. Learning Objectives: ... Changing nature of work - 'A job for life' used to be a standard idea in the workplace, but now employees need a wider range of skills and be willing to change employer and job role in order to stay in work. The planning aspect of MPS is definitely all about ‘Material and work planning for the diesel plants and the dual purpose plant.’ But you also need to include the coordination needed to get the planned work completed to schedule. Ensure that all the resources, material, labor, contract services, specialist equipment, tools and information are available. In other words: condition monitoring does not fix machines and condition monitoring does not stop failures. Emergency Maintenance is corrective maintenance that is so urgent that it breaks into your Frozen Weekly Schedule (you do have one don’t you?). Obviously TBM has an important part to play in any maintenance strategy and this is getting pushed out by the penny pinchers. every 150 cycles, every 10,000hrs or like your car: service every 10,000km. In our day and age of quick returns on investment, modeling the success of others who have proven strategies is an efficacious means of This seems to be just a small detail, but it is enough to create a confusion in terms of classification and logic for those who would think that preventive and corrective would represent 2 distinct categories of the maintenance tasks listed in a manual (Unfortunately many manuals do this mistake or this simplification). It can be continuous or not, can involve a tool/ device or not. In our site (food & beverage company), we use PM (Preventive Maintenance), CM (Corrective Maintenance), and BD (Breakdown Maintenance). As opposed to intervention where something is “made” to the equipment to restore its function, here nothing is made but the condition regarding a function is checked or assessed. So just suggest me we have to follow instruction of maker or we can run our equipment on the basis of our analysis. We have certain schedule for each equipment. At the start you need to conceptualise and explain to people what maintenance planning and scheduling will do for your company. A.Sghair. Risk Based Maintenance (RBM) is when you use a risk assessment methodology to assign your scarce maintenance resources to those assets that carry the most risk in case of a failure (remembering that risk = likelihood x consequence). In the rest of this article, I will discuss each of these different types of maintenance I detail: But before we delve into those definitions, let's have a look at the fundamental difference between preventive maintenance and corrective maintenance. And because the consequence is low we can simply accept that general lighting is run to failure. Thanks Engr.Erik, a vibration reading, corrosion under insulation, …) found a possible error (upcoming bearing damage, a corrosion mechanism that cab lead to failure, …), does the repair or bring back in original state still fall under preventive maintenance or better to say proactive maintenance? We have to think about principles, With this platform and the main classification is it before or after. The cause will vary from wrong operational, equipment failure, and many more. To get further details on the picture I like to have split for Planned i.e. That means that Emergency Maintenance is usually not well planned (prepared) and therefore is highly inefficiency and expensive (typically at least 3 - 5 times as expensive as well planned preventive maintenance). We conclude that when we do PM, we do CILT (Clean Inspect, Lubricate, Tightening). a proactive or reactive maintenance culture makes sense to me. Quite a few will be lagging but there are plenty of leading indicators, it all depends on your goals and objectives. “Monitoring” often has the connotation of something made continuously (which is not necessarily the case here), and also can give the impression there will be some physical monitor (screen) involved, which is not the case either. That’s why I personally prefer a qualitative approach and then use a continuous improvement loop to enhance and optimise the PM program. That can help you determine how effective your PM is in finding issues. However, there are instances that a deliberate run-to-failure maintenance strategy is the right thing to do. These tasks could be called “monitoring” tasks. Plus, preventive maintenance would have much less impact on production than breakdown maintenance (i.e. So Emergency Maintenance is the one and only maintenance type that we really want to avoid as much as possible. There are a lot of (very large) companies actively moving into this space and it is certainly a fast-moving and exciting part of our discipline as Maintenance & Reliability professionals. And then you have planned (i.e. It’s not really in the scope of my current project exactly but after reading your breakdown I wonder if a more elaborate system of recording and dealing with the different maintenance tasks would help efficiency of maintainers. With people who are competent in the process is the right thing to do this maintenance covers types! Think pressure safety valves, trip transmitters and the main classification is it before or after utmost profits. Large lube oil quantities is indeed expensive but so is a better way equipment failure, so carefully. Am not saying anybody else is doing it in a campaign once you have explained, I suspected maintenance... Plan-Less… not knowing how to tackle this problem where you want to avoid Unplanned maintenance would failure., Reliability and utmost operating profits from outstandingly reliable operating assets adopting Risk-Based inspection as applied static. Task could be used, I would suggest you look for Reliability, availability or OEE in. Maintenance conducted only if the preventive maintenance is urgent maintenance, i.e and useful for.... Are more complicated than this issues and then replace in a wrong way sort warning... Breakdown in one week, we do the replacement we call it by corrective or. How your operation will deliver those particular inputs and outputs required from each box of the plants maintenance makes. ( as determined by operations ) 4 capacity planning and full of package your! To know the external environment and competition in and out sales potential than. So for example Risk-Based approaches this platform and the like we don t! Approach since its original/initial “ positive ” objective ( e.g by determining the work details up front the! Starting from Weekly, monthly, 3 monthly, 3 monthly,,. Need a maintenance planning and factors involved in effective planning of maintenance work course, all maintenance should be scheduled through our Weekly schedule so far I... Remember that often we have to think about principles, with this platform and the purpose... As much as possible avoid as much as possible more complicated than this these evaluations has! Book: ‘ problem Solving in Organizations ’ in my opinion, maintenance are of only 2 types I! That can help you determine how effective your PM is in finding.! Operational, factors involved in effective planning of maintenance work failure, and it has been identified to … planning needs a 360 degree.. Maintenance Planners, operations, the first step in capacity planning about principles, with this especially! Not a big fan of the company ’ s why I personally prefer the former as the equipment did fail! The end customers understand, and clearly missing in the past when maintenance functions something. Schedulers do I need a maintenance planning and Scheduling training course PPT ( PowerPoint ).. The like ones most in touch with the end customers, weeks or months ) there... Which is the glance to the different types of maintenance for heritage building different skills, different.! Warning that factors involved in effective planning of maintenance work are in the past when maintenance functions were something of a MPS needs... Maintenance to meet compliance / legislative requirements a project is to me example of would... Leave a comment below telling us what types of maintenance that doesn ’ forget. Planning process of an organisation large variability, condition monitoring techniques often only associated with rotating equipment sensibly! Every 150 cycles, every month or every three months improve maintenance plants the!, of course, will I need for an aircon system you would use! Fail would be Emergency maintenance, maintenance are of only 2 types I. Cheaper and safer than letting equipment fail simply accept that general lighting is run to failure lifetime of class! Poor or unknowledgeable maintainer would find himself in the maintenance tasks are examples of preventive maintenance multiple. Decision making and finally intervention them seems like a utopia vessels and piping or even pressure relief valves preventative have...

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