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MAINTENANCE CONCEPTS

“Do You Know The Real Costs Of The Maintenance Category You Are Currently Using?”
The path to equipment reliability requires:
1. Understanding where you are now? 2. Where do you want to be? 3. How and when will you get there?

There are four basic Maintenance Concepts:

UNPLANNED Maintenance
A conscious decision to do nothing until failure Extreme To High Costs
PREVENTIVE Maintenance
Change parts and fluids on a schedule High To Moderate Costs
PREDICTIVE Maintenance
Anticipate rather than react Good Cost Reduction
Hybrid
Best of preventive and predictive Most Efficient Cost Reduction

• Where are you now? • Do you have a plan? • What are your short-term goals?
• What is your current cost? • Is the plan realistic and doable? • What tools will you use?
• Do you have vendor support and help?

HOW WILL YOU MEASURE SUCCESS?


How you measure success can be based upon what constitutes success in your program. The possibility of real reduction in
the cost for maintenance (parts and labor), energy, downtime, and scrap. Another advantage, could be improvements or
increases in production time, equipment availability, safety, and/or overall fluid life.
“Applying Maximum Equipment Life And Reliability As The Ultimate Goal”
UNPLANNED Maintenance
A conscious decision to do nothing until failure!

Very High Maintenance Cost Short Component Life Reactive Maintenance


• Overtime • Minor problems progress to failure • Fix it when it breaks
• Lost production • Repetitive repairs • No time for failure analysis
• Catastrophic repair cost • No historical data to learn from
• High energy cost
• High inventory parts

©2005
E-mail: information@bluemoonsystems.com • 1249 Oliver Street • Bowling Green, KY 42104 1
PREVENTIVE Maintenance
Maintenance based on time, distance traveled, or mile intervals

Moderate High Maintenance Cost Short Component Life Reactive Maintenance


• Over or under maintained equipment • Repair start-up problem • UNPLANNED Maintenance
• Inspections may create more • Unlimited historical information • No root cause analysis
problems than are corrected • Exposure to external supply
and storage problems
• Energy cost are still high
• Repetitive repairs
• Production loss

THE ISSUE
“Do You Know That Every Component Is Unique?”
Do you believe that every component is unique, or that all like components will develop the same problems at the same time?
If you believe that all components are unique, then you will probably recognize that this maintenance concept is not cost effective.
But if you believe that all like components develop the same problems at about the same time, then most likely you will feel
that PM is cost effective.

PREDICTIVE Maintenance
Condition based maintenance

Reduced Maintenance Costs Increased Component Life Proactive Reliability Assessment


• Less overtime • Minor problems corrected early • Analysis and anticipate rather
then react and repair
• Significantly reduced repetitive • Historical data encourages • Trending and developing unique
repairs purchase of equipment component action
• Increased production
• Decreased energy cost • Designed for real life application
of that equipment
• Decreased repair cost

Proactive reliability assessment techniques rely on technology, experience and common sense. That is why most
companies are integrating the skills of maintenance, engineering, and tribology into their management practices. If
they further enlist the skills of their vendor’s knowledge and experience, they maximize the chances for successful
realization of their goals.

©2005
E-mail: information@bluemoonsystems.com • 1249 Oliver Street • Bowling Green, KY 42104 2
PREVENTIVE, PREDICTIVE OR HYBRID?
“Do You Know The Real Cost Or Savings Of The Maintenance Strategy You Are Currently Using?”
PREVENTIVE Maintenance

PM is based on time or mileage intervals to perform specific maintenance tasks and fluid changes, adjustment,
inspections, and overhauls. It is preventive in that it presumes that these actions will prevent major component
failures.
Scheduling is usually based on one or more of the following:
• Warranty requirements • Maintenance experience • Advice of fluid and filter manufacturers
Overall it has been a successful practice. But it is not necessarily the most cost effective practice. Failures still
occur, maximum reliability and life expectancy may be sacrificed by PM programs.

One of the most important steps in going from PM to PDM or Hybrid is to develop a root cause analysis process.
You can’t develop a program to extend component life unless you know what shortens equipment life.

“Which Maintenance Concept Would Be Most Cost Effective In Your Operation?”


PREDICTIVE Maintenance

PDM is condition based maintenance. Maintenance is still scheduled, but based upon the individual components
proven needs, rather than a recurring schedule. Condition is usually determined by a combination of non-invasive
techniques; oil analysis, vibration, electronic system testing, operational data recording (temperature, speed load,
working time verses idle time.) The data is evaluated in terms of trends, and or deviation from normal trends. A
decision is then made to take action or not. In all cases minor problems can be corrected before they cause a major
problem. You can call it TRUE PREVENTIVE maintenance. But, since it involves the process of analysis and antici-
pate, it is in fact PREDICTIVE maintenance. In some cases once an abnormal trend develops probabilities can be put
in place that will pinpoint a time when action will have to be taken.

PROACTIVE Maintenance
Hybrid best of Preventive and Predictive maintenance

This combines the best of both PM and PDM program. It is what works best from each program for your
program... The best and most cost effective way for your maintenance program to work.

©2005
E-mail: information@bluemoonsystems.com • 1249 Oliver Street • Bowling Green, KY 42104 3
DEVELOP A PLAN • EXECUTE THE PLAN
TEST AND CONTINUALLY REASSESS THE PLAN
Identify current maintenance status and detailed cost
Develop short and long range goals, with a time schedule
Select the maintenance path required to meet your goals

• PREVENTIVE Maintenance PM • PREDICTIVE Maintenance PDM


• PROACTIVE Maintenance Hybrid of Both

Determine manpower and training requirements


Determine which tools are required to meet your goals

• Applicable hardware and software


• Root cause analysis and documentation process
• Fluid and wear particle analysis

©2005
E-mail: information@bluemoonsystems.com • 1249 Oliver Street • Bowling Green, KY 42104 4