RCM

The RCM process described in the DOD/UAL report recognized three principal risks from equipment failures: threats

to safety, to operations, and to the maintenance budget.

Modern RCM gives threats to the environment a separate classification, though most forms manage them in the same way as threats to safety. RCM offers five principal options among the risk management strategies:

Predictive maintenance tasks, Preventive Restoration or Preventive Replacement maintenance tasks, Detective maintenance tasks, Run-to-Failure, and One-time changes to the "system" (changes to hardware design, to operations, or to other things).

Maintenance types[edit]
Generally speaking, there are three types of maintenance in use:

Preventive maintenance, where equipment is maintained before break down occurs. This type of maintenance has many different variations and is subject of various researches to determine best and most efficient way to maintain equipment. Recent studies have shown that Preventive maintenance is effective in preventing age related failures of the equipment. For random failure patterns which amount to 80% of the failure patterns, condition monitoring proves to be effective. Operational maintenance, where equipment is maintained in using. Corrective maintenance, where equipment is maintained after break down. This maintenance is often most expensive because worn equipment can damage other parts and cause multiple damages.

Preventive maintenance[edit] Main article: Preventive maintenance

Preventive maintenance is maintenance performed in an attempt to avoid failures, unnecessary production loss and safety violations. The effectiveness of a preventive maintenance schedule depends on the RCM analysis which it was based on, and the ground rules used for cost-effectivity.[4]

Further information: Planned maintenance Corrective maintenance[edit] Repair shop Main article: Corrective maintenance

Corrective maintenance is probably the most commonly used approach, but it is easy to see its limitations. When equipment fails, it often leads to downtime in production. In most cases, this is costly business. Also, if the equipment needs to be replaced, the cost of replacing it alone can be substantial. It is also important to consider health, safety and environment (HSE) issues related to malfunctioning equipment. Corrective maintenance can be defined as the maintenance which is required when an item has failed or worn out, to bring it back to working order. Corrective maintenance is carried out on all items where the consequences of failure or wearing out are not significant and the cost of this maintenance is much greater than preventive maintenance. Corrective maintenance is the program focused on the regular task that will maintain all the critical machinery and the system in optimum operating conditions. The major objectives of the program are to 1.Eliminating breakdown 2.Eliminating deviation 3.Eliminating unnecessary repairs 4.Optimize all the critical planned system
Reliability centered maintenance[edit] Main article: Reliability centered maintenance

Reliability centered maintenance is an engineering framework that enables the definition of a complete maintenance regime. It regards maintenance as the means to maintain the functions a user may require of machinery in a defined operating context. As a discipline it enables machinery stakeholders to monitor, assess, predict and generally understand the working of their physical assets. This is embodied in the initial part of the RCM process which is to identify the operating context of the machinery, and write a Failure Mode Effects and Criticality Analysis (FMECA). The second part of the analysis is to apply the "RCM logic", which helps determine the appropriate maintenance tasks for the identified failure modes in the FMECA. Once the logic is complete for all elements in the FMECA, the resulting list of maintenance is "packaged", so that the periodicities of the tasks are rationalised to be called up in work packages; it is important not to destroy the applicability of maintenance in this phase. Lastly, RCM is kept live throughout the "in-service" life of machinery, where the effectiveness of the maintenance is kept under constant review and adjusted in light of the experience gained.

MRO software[edit]
Main article: MRO Software

In many organizations because of the number of devices or products that need to be maintained or the complexity of systems, there is a need to manage the information with software packages.

This is particularly the case in aerospace (e.g. airline fleets), military installations, large plants (e.g. manufacturing, power generation, petrochemical) and ships. These software tools help engineers and technicians in increasing the system availability and reducing costs and repair times as well as reducing material supply time and increasing material availability by improving supply chain communication. As MRO involves working with an organizations products, resources, suppliers and customers, MRO packages have to interface with many enterprise business software systems (PLM, EAM, ERP, SCM, CRM). One of the functions of such software is the configuration of bills of materials or BOMs, taking the component parts list from engineering (eBOM) and manufacturing (mBOM) and updating it from "as designed through "as built, "as delivered", as maintained, and as used. Another function is project planning logistics, for example identifying the critical path on the list of tasks to be carried out (inspection, diagnosis, locate/order parts and service) to calculate turnaround times (TAT). Other tasks that software can perform:

Planning operations, Managing execution of events, Management of assets (parts, tools and equipment inventories), Knowledge-base data on: o Maintenance service history, o Serial numbered parts, o Reliability data: MTBF, MTTB (mean time to breakdown), MTBR (mean time between removals), o Maintenance and repair documentation and best practices, o Warranty/guarantee documents.

Many of these tasks are addressed in computerized maintenance management systems (CMMS). Data standards have been developed around these activities, most notably EAMXML and MIMOSA.
What is the definition of "autonomous maintenance"? Maintenance that is performed by the machine operator rather than the maintenance staff. Autonomous maintenance includes tasks such as lubricating and tightening machine parts. Learn more about autonomous maintenance in the class Total Productive Maintenance Overview 150 below.

autonomous maintenance

Maintenance that is performed by the machine operator rather than the maintenance staff. Autonomous maintenance includes tasks such as lubricating and tightening machine parts. The percentage of time a machine is actually able to produce parts out of the total time that it should be able to produce. This number includes breakdowns, setups, and adjustments. The expected good state of repair that equipment should possess in order to produce quality parts in a timely manner. Under TPM, operators are expected to maintain their machine's basic condition. Maintenance performed on broken machines to restore them to working order. A specialized grouping of people, machines, and materials. The purpose of a cell is to efficiently produce small batches of parts. Validation that a person or company has achieved a certain standard. Certification may be awarded by a school, a professional organization, or other governing body. Replacing ineffective practices, machines, or other manufacturing components with effective ones to attain ongoing, measurable gains. Organizations must constantly measure the effectiveness of processes and strive to meet more difficult objectives to satisfy customers. The period of time when a machine or a factory is not operating and is not producing. An outside organization or individual that receives a product or service from the company. A process applied to a manufactured part that goes beyond making the part to the correct shape and size. Sanding, heat treating, and painting are examples of finishing. A targeted list of activities that promotes organization and efficiency within a workspace. The Five S terms are sifting, sorting, sweeping, standardizing, and sustaining. A department or individual within the company that relies on others to satisfy the external customer.

availability

basic condition

breakdown maintenance

cell

certification

continuous improvement

downtime

external customer

finishing

Five S

internal customer

International Organization for Standardization ISO. An organization based in Switzerland that develops and

publishes standards for its international membership base. The belief that an organization must maintain a focus on change for the better or continuous improvement. An improvement tool that brings together employees from various departments to examine a problem, propose solutions, and implement changes. Kaizen events usually take place over one or two days. An approach to manufacturing that seeks to improve product quality and productivity, reduce cost, and eliminate waste. The necessary and basic support and repair of machines. Maintenance includes tasks such as lubricating, adjusting, and replacing parts. Machine engineering and design that is based on preventing the need for maintenance or for ease of access to machine parts so that maintenance may be carried out easily. Application of the principles of total productive maintenance to the administrative areas of the company. OEE. The percentage of equipment's availability, quality, and performance multiplied together. The rate parts are produced divided by the machine capacity. This number includes the number of parts produced in a given time, reduced speeds, idling, and short-term stoppage for jams and other problems. Maintenance performed on a calendar basis. Maintenance that is performed purposely and regularly in order to prevent a machine from deteriorating or breaking down. Maintenance performed based on the known and expected behavior, condition, and history of the machine. Maintenance performed while a machine is still in working order to keep it from breaking down. Preventive maintenance includes lubricating, tightening, and replacing worn parts. A material management system in which parts are not delivered to machines until they are needed. Pull systems place demands on

kaizen

kaizen event

lean

maintenance

maintenance prevention

office TPM

overall equipment effectiveness

performance rate

periodic maintenance

planned maintenance

predictive maintenance

preventive maintenance

pull system

maintenance to keep machines up and running. An approach to manufacturing that focuses on customer satisfaction. Quality products conform to specifications, are free of defects, and meet the requirements of their anticipated use. Maintenance focusing on tasks that keep machines producing quality, error-free parts. The percentage of good parts out of the total produced. This number includes time lost to defects and the time it takes from startup to normal production. The practices and policies that a company puts in place in order to preserve the health and well-being of employees, equipment, and facilities. Areas in manufacturing where the greatest amounts of materials and time are wasted. They include breakdowns, setup and adjustment time, idling and minor stoppages, speed reduction, quality defects, and startup losses. A manufacturing improvement method that increases production and reduces waste through continuous attention to the condition of machines and processes. TPM's main goal is to maximize equipment usefulness across its lifespan.

quality

quality maintenance

quality rate

safety

six big losses

total productive maintenance

Autonomous Maintenance
What is Autonomous Maintenance?
Autonomous Maintenance is the second of the eight pillars of TPM. It follows a structured approach to increase the skill levels of personnel so that they can understand, manage and improve their equipment and processes. The goal is to change operators from being reactive to working in a more proactive way, to achieve optimal conditions that eliminate minor equipment stops as well as reducing defects and breakdowns.

How is the Pillar implemented?

The Autonomous Maintenance pillar activity is broken down into three phases and is owned by the team who use the equipment on a daily basis. The first phase establishes and maintains basic equipment conditions through restoration and eliminating causes of forced deterioration and sources of contamination. Standards are introduced for cleaning, inspection, tightening and lubrication to ensure the conditions are sustained. The second phase increases the capabilities of the team by training them in the detailed operating principles of the equipment and then improving the standard basic condition. During the third phase, the operators take total ownership of the equipment as self-directed teams, continuously improving equipment condition and performance to further reduce losses.

What are the benefits of the Pillar?

The deployment of Autonomous Maintenance will improve Overall Equipment Effectiveness (OEE) by reducing performance loss and increasing equipment availability. In addition there will be measurable improvement to employee engagement and capability levels.

Engineering[edit]
Road repair In telecommunication, commercial real estate and engineering in general, the term maintenance has the following meanings: 1. Any activity such as tests, measurements, replacements, adjustments and repairs intended to retain or restore a functional unit in or to a specified state in which the unit can perform its required functions.[3] 2. For material all action taken to retain material in a serviceable condition or to restore it to serviceability. It includes inspection, testing, servicing, classification as to serviceability, repair, rebuilding, and reclamation.[3] 3. For material all supply and repair action taken to keep a force in condition to carry out its mission.[3] 4. For material the routine recurring work required to keep a facility (plant, building, structure, ground facility, utility system, or other real property) in such condition that it may be continuously used, at its original or designed capacity and efficiency for its intended purpose.[3] Manufacturers and Industrial Supply Companies often refer to MRO as opposed to Original Equipment Manufacturer (OEM). OEM includes any activity related to the direct manufacture of goods, where MRO refers to any maintenance and repair activity to keep a manufacturing plant running. Industrial supply companies can generally be sorted into two types:

the ones who cater to the MRO market generally carry a broad range of items such as fasteners, conveyors, cleaning goods, plumbing, and tools to keep a plant running. OEM supply companies generally provide a smaller range of goods in much larger quantities with much lower prices, selling materials that will be regularly consumed in the manufacturing process to create the finished item.