Preventive Maintenance Planning
1
Maintenance policies
Maintenance Policies
(1) (5)
Failure-Based Total-Based
Reactive (ReM): Global (GM):
(3)
- RTF - Optimization Approach
Condition-Based
- CM
Predictive (PdM):
- BD (2) - TPM
- Oil analysis
:: Time-Based ::
- Vibration analysis
Preventive (PM): - Temperature analysis (4)
- Calendar: - Pressure analysis Risk-Based
Weekly - Wear analysis Proactive (PaM):
Monthly - Efficiency analysis - RCFA
:: :: - FMEA \ FMECA
- Running: - HAZOP
1000 R.H. - RCM \ RCM2
1000 K.M. - RBI :: ????
::
Classification of maintenance policies.
[Venkatesh 2003, Waeyenberg and
ME091301 PintelonManagement
Maintenance 2004, and Gomaa et al. 2005] 2
Preventive & Predictive Maintenance
Maintenance
Policies
Preventive Corrective
Maintenance Maintenance
Indirect Preventive Predictive Maintenance
Direct Preventive
Maintenance/ Condition
Maintenance Breakdown
Based Maintenance (CBM)
Maintenance
Fixed Time
Maintenance
Subjective Objective
Condition Condition Planned
Monitoring Monitoring Maintenance
Off-line
Essential Care Monitoring
On-line
Monitoring
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Definition
Essential Care adalah kompilasi dari proses yang
akan mencegah terjadinya kegagalan.
Lubrication, alignment, balancing, cleaning, and
operating procedures, adjustments and installation
procedures. Essential Care dapat mencegah kegagalan
(memperpanjang umur peralatan).
Fixed Time Maintenance Peralatan diganti
secara berkala pada interval waktu yang tetap.
Pemeliharaan tepat waktu dapat mencegah
terjadinya kegagalan (tanpa memperpanjang
umur)
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Definition
Objective Objective methods are for example
vibration analysis, ultrasonics, and temperature-,
pressure-, voltage- and ampere readings.
Subjective inspections are look, listen, feel and
smell
Preventive Maintenance is essential care and
fixed time maintenance together. Both essential
care and fixed time maintenance PREVENTS (both
prevent) FAILURES, while Conditions Monitoring
only DETECTS FAILURES EARLY.
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Preventive Maintenance Overview
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Preventive Maintenance
Why PM should be done?
To prevent To detect To discover
equipment failures early failures hidden failures
Time-Directed Condition-Directed Failure Finding
Maintenance (TD) Maintenance (CD) (FF)
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Failure
What is failure?
Suatu kondisi yang tidak sesuai dengan yang
diinginkan
what does the relationship between failure
rate and life time of equipment look like?
Bathtub curve
Do all equipments have same failure pattern?
NO!
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Lifetime Failure Rates
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Failure Patterns
Traditional Concept
Distinct aging during useful life
No infant and wear out
Low failure follow
by constant hazard
Constant failure
Infant failure follow
by constant hazard
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Failure Patterns
Q: How the failure patterns affect maintenance people?
A: Major challenge facing maintenance people is?
To learn what techniques are used
To decide which method are worthwhile and
which are not in their own organizations.
Right choices, it is possible to improve asset performance
and at the same time contain and even reduce the cost of
maintenance.
Wrong choices, new problems are created while existing
problems only get worse.
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Total Maintenance Cost
Cost
Total Maintenance Cost
PM Cost
Down Time Cost
CM Cost
Best level
PM level Reliability
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2 hal yang perlu dipertimbangkan
Q: apa tujuan PM?
Q: Bagaimana
Mengidentifikasi PM?
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Tujuan PM
Untuk meminimalkan jumlah kerusakan peralatan kritis
Untuk mengurangi hilangnya produksi yang terjadi saat
terjadi kegagalan peralatan
Meningkatkan produktifitas seluruh Capital equipment
Untuk mendapatkan data yang berarti terhadap
catatan/history semua Capital equipment
memungkinkan perencanaan dan penjadwalan
pemeliharaan yang lebih baik
Memastikan keselamatan dan kesehatan kerja yang
lebih baik
Untuk memaksimalkan pengembalian investasi modal
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Karaktristik Plant yang membutuhkan program PM
Manfaat mesin dan peralatan yang rendah karena
pemberhentian kerja yang tak terjadwal
Waktu tunggu atau waktu menganggur operator
yang tinggi peralatan atau mesin downtime
Kenaikan biaya perbaikan peralatan karena
rutinitas kerja seperti pelumasan, cleaning
Turunnya produktifitas karena kurang perawatan
yang memadai
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PM: An Example
First, hitung jumlah kerusakan yang terjadi
untuk setiap kebijakan PM.
Next, hitung biaya yang diperlukan secara
rinci, biaya perawatan preventif, dan biaya
total untuk setiap kebijakan PM.
Finally, identifikasi kebijakan yang
meminimalkan total biaya per satuan waktu
(misal, per minggu).
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Expected Number of Breakdowns
n
Bn N( p n ) B(n 1) p1 B(n 2) p 2 ... B1p (n 1)
1
where:
Bn = perkiraan jumlah kerusakan untuk masing-
masing kebijakan PM
pn = Peluang terjadinya gangguan setiap
periode n
N = jumlah mesin dalam kelompok
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Example: PM Frequency
It costs $6,000 to perform PM on a group of four
machines.
The cost of down time and repairs, if a machine
malfunctions between PM inspections, is $8,000.
How often should PM be performed to minimize
the expected cost of malfunction and the cost of
PM?
(The machines’ breakdown history is on the next
slide.)
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Example: PM Frequency
Machine Breakdown History
Weeks Probability That a
Between PM Machine Will Malfunction
1 0.2
2 0.3
3 0.5
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Example: PM Frequency
n
Bn N( p n ) B(n 1) p1 B(n 2) p 2 ... B1p (n 1)
1
B1 = 4(0.2) = 0.800
B2 = 4(0.2 + 0.3) + 0.8(0.2) = 2.160
B3 = 4(0.2 + 0.3 + 0.5) + 2.16(0.2) + 0.8(0.3) = 4.672
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Example: PM Frequency
Exp. Weekly
PM Exp. Number Exp. Weekly Total
Every Number of BDs Cost of Cost Weekly
n Wks. Of BDs per Wk. BDs of PM Cost
1 0.800 0.800 $6,400 $6,000 $12,400
22 2.160 1.080 8,640 3,000 11,640
3 4.672 1.557 12,456 2,000 14,456
The policy that minimizes total weekly cost is:
perform PM every 2 weeks.
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Assignment#2 (Individual)
Find a paper in journal concerning to the
preventive maintenance.
Write a summary with the maximum length of
10 pages A4 format.
Prepare for 15 minute presentation
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References
Norman Gaither & Greg Frazier, Operations
Management, Edition 9, Academic Internet
Pub Inc, 2001.
GMM or CMS, Slides prepared by Dr. Attia
Hussien Gomaa, Engineering service -
American University in Cairo (AUC).
Anthony Kelly, Maintenance Systems and
Documentation, Elsevier, 1st Edition 2006.
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