MAINTENANCE PRINCIPLES

Ing. ORLANDO DIAZ PARRA

UPTC DUITAMA
 BACKGROUND OF MAINTENANCE

Maintenance is a scientific activity :

Susceptible used measurement variables.
Rationalizes the use of material resources.
It depends organized, coherent and systematic actions
Develops human potential.
Seeks the protection of the environment.
Uses computer resources.
 PREVENT AND PREDICT
REPAIRMAN
CAPACITY

MAINTENANCE ORGANIZED

80 / 20
 DEFINITIONS

Maintenance is a set of actions, operations and attitudes designed to

make or restore a equipment or machine to a specific state, enabling it to
ensure a particular service.
Maintaining it perform operations such as cleaning, lubrication,
inspection, maintenance and improvements to equipment and goods to
ensure continuity and guarantee the production quality
Maintaining quality is intelligently use planning, scheduling and control,
so as to improve the effectiveness and productivity, reducing downtime
and maintenance costs.
The objective of maintenance is to get good profits by keeping
equipment and plants in the highest degree of availability, productivity and
competitiveness using equipment and more efficient technologies and cost-
effective.
 THE PURPOSE OF MAINTENANCE

The main purpose of maintenance is to keep the machine to

ensure that the role within the production process fully complies,
this means:

Protection and conservation of investments,

Ensuring increased productivity,
The safety of operating the scheduled time,
Most profitable operations,
Ensuring the safety of operators and
Compliance with standards of environmental conservation
 THE PURPOSE OF MAINTENANCE

To achieve this, the maintenance plan must contain:

Establishment of objectives,
Application of administrative grounds,
Planning and control systems,
Concrete and effective maintenance programs,
Adequate supply of materials and parts,
Proper control of costs and budgets and
A simple and objective information system.
 THE PURPOSE OF MAINTENANCE

To achieve this, the maintenance plan must answer:

what to do?
How to do it?
When do I do?
With whom and how to do it?
As running what is done?
 THE PURPOSE OF MAINTENANCE
Maintaining the hand of administration should contribute to the
fulfillment of basic business functions:

PRODUCE,
SELL,
OBTAINING FINANCIAL AND PERSONAL EARNINGS,
MANAGE ,
GROW and
ENDURE
 WHY YOU SHOULD MAINTENANCE?
All machines and equipment are exposed during its lifetime to cause
deterioration are three types:

internal agents as the relative movement, cavitation,

erosion, thermal shock, mechanical vibration,
NORMAL
pressure, etc.
OR
REGULAR external agents such as air pollution, salt corrosion,
solar heat, dust, etc.

ABNORMAL Because conditions of intentional or unintentional

OR operation, such as neglect, overloading, poor
IRREGULAR operation, poor maintenance, etc.

Due to uncontrollable causes such as earthquakes,

ACCIDENTAL
tsunamis, hurricanes, rain or drought, etc.
 RATIONALE OF MAINTENANCE
The greater the investment: real depreciation decreases.
The higher automation: least amount of labor used to operate but
maintenance costs are increased.
The more complex the equipment: require more specialized services.

The larger production series: any link in the chain fails, it will cause a
general stop.
The higher the quality requirements: defects in the
machines generate quality defects.
The higher inventory costs: decrease required safe stocks
of spare parts and raw materials in warehouses.

The more the environment is affected: it is a current requirement.

 FACTORY ENGINEERING
Maintenance engineering is part of the development chain:

Factory Engineering is defined as that branch of knowledge that

transforms natural resources for them at the service of man.
Research Engineering: looking for materials, equipment, procedures and
techniques to improve production systems.
Development Engineering: applying the results of research on the
exploitation of natural resources.
Design Engineering: developing new processes and transfers them to
plans and specifications for equipment manufacturing and industrial
plants.
Construction Engineering: build buildings and mounted equipment to be
used in the transformation of natural resources.
Production Engineering: installed equipment operates and is exploring
ways to obtain the best yields and greater profitability.
Maintenance Engineering: maintaining equipment and buildings in the
best operating conditions.
 Maintenance Engineering can be defined as the work of managing
and developing maintenance programs for equipment, tools and
facilities of a company, therefore its main objectives are:

Permanently maintain equipment and facilities at its best, to

avoid unproductive time stop,
Prolonging the life of the equipment permanently and efficient
operation,
Make emergency repairs as soon and efficiently as possible,
Suggest and plan improvements in equipment to reduce the
chances of failure and increase productivity,
Carry out systematic inspections of the factory with sufficient
control intervals, keeping adequate records,
Check the direct cost of maintenance, through the proper and
effective use of time, materials, services and human resources.
 HISTORICAL EVOLUTION
OF MAINTENANCE

MAINTENANCE YOUR SHARED DEVELOPMENT HAS INDUSTRY: NEW

TRENDS AND NEW IDEAS EVOLVE HAVE FORCED.
 THE FIRST GENERATION
(Before 1950)

Maintenance is considered a minor activity and cost that must be

incurred.

"Repair in case of failure"

equipment are carried a point of failure.

Maximum use of spare parts and high consumption of resources.
Maintenance requires a lot of staff
maintenance costs are not measured.

"Maintenance is seen as an expense"

 THE SECOND GENERATION
(1950 to 1970)
Production processes need greater availability of the machines and
longer equipment at lower costs.

"It is necessary to prevent equipment failure"

Increased availability of machinery.

Longer equipment.
Lower costs to maintain the equipment.

To prevent equipment failure were planned longer preventive

shutdowns or of periodic maintenance.

"Maintenance is a necessary expense"

 THE THIRD GENERATION
(1970 to 2000)
Companies require products of the highest quality and at lower
prices, for that you must have greater availability and reliability
of machinery and equipment.

"Maintenance is based on the condition of the equipment"

Increased availability and reliability of equipment.

Safer operation and product quality.
Environmental Protection.
Use of new technologies and strategies.

"Maintenance is a very profitable investment"

 THE FOURTH GENERATION
(2000 - present)
Companies seek the greatest value of its assets. They seek to
ensure that all business objectives are considered balancing
operating costs, reliability and security.

"Maintenance business oriented"

Decision making under ambient few data and historical quality.

reliability and techniques methods are adopted.
Companies create their own databases and model the behavior of
their systems.
Asset Management British Standard Asset Management PAS-
55.

"maintenance coordinates its objectives whit the business"

EVOLUTION OF BUSINESSES AND
MAINTENANCE
 EVOLUTION OF BUSINESSES AND MAINTENANCE

The maintenance history is confused with the development of enterprises

processing of goods in which the following steps occur:

STAGE PRODUCTION MAINTENANCE

ORIENTATION TO ORIENTATION TO..

I product repair unexpected failures

II production prevent, predict and repair failures
III productivity the tactics establish maintenance
IV competitiveness implement a strategy, compared
V technological innovation apply science and high technology
VI Integral management and operation in a coordinated manner across the

entire enterprise Asset Management

 STAGE I
APPROACH MAINTENANCE ACTIONS

Apparition of maintenance tools,

It hires and trains personnel in mechanical, electrical, mechatronics,
pneumatics, hydraulics, electronics, etc.,
It used work orders, specialized tool and parts stores,
techniques and technologies themselves develop the company,
equipment are identified, maintenance plans are established,
defined safety recommendations,
hiring plans and vendor management are realized,

Production is dedicated to make products and services generate.

 STAGE II
ORIENTATION ACTIONS PLANNED
The unforeseen failures are considered the biggest problem of production,
prevention and prediction actions of faults are developed: routine inspections,
preventive plans, technical measurements, assessment of the condition and
status of equipment, nondestructive testing, registration of technical data,
equipment monitoring, replacement of items before fails, control elements
useful life, settings in function before failure, etc.,
corrective, modifying and predictive actions differ.
the condition of critical equipment is established, according to the condition
of the equipment in the production process and the advisability of
implementing predictive techniques or statistical evaluation is assessed.
appropriate work orders are generated predictive process and management
system is founded.

Production structure a productive system.

 STAGE III

APPROACH TACTICS MAINTENANCE ORGANIZATION

Companies with more mature adopt a structure for a sequential, logical and
organized development.
Businesses evolve to adopt a tactic maintenance as : TPM, RCM, Combined,
Productive, Centred on Risk, Centred on Objectives and Results, etc.
The evolution is not to move from one tactic to another, but to adopt as their
own that combines the best practices of several of them, the TPM is the most
basic of all.

To produce its objective is to optimize the exploitation of productive

factors.
 STAGE IV

APPROACH INTEGRATED LOGISTICS, MAINTENANCE STRATEGY

the historical record of failure and repair is implemented,

measurement systems under its own and international parameters are set by
comparing with other companies to establish the level of success both in operation
and maintenance.
Maintenance develops a strategy to in a holistic manner control its elements, actions
and tactics.
the real needs of staff development and training are detected for maintenance
personnel to reach adequate levels of qualification for applying new technologies in
management processes.
Production seeks to improve its competitiveness,
managers and all corporate areas involved to obtain greater efficiency and cost
reduction.
The set of actions and efforts achieved in a logistical way leads to Terotechnology
(Maintenance Integral Logistics)
 STAGE V

APPROACH THE SKILLS AND COMPETENCES MAINTENANCE

It consolidates the achievements of FMEA (Analysis modes, effects, and criticalities

cause failures), RCFA (Analysis of root causes of failures) and RPN (Risk Priority
Number),
It is likely that a comprehensive maintenance strategy is implemented based on
processes,
It works in all sections of the company with boxes and control panels under a strategic
direction.
Implements production techniques and cutting edge technologies as adjusted
production to demand, inventory management, ABC inventory control systems in time,
demand forecasts.

best practices that increase productivity, profitability, competitiveness

and technological innovation are considered.
 STAGE VI

APPROACH ASSET MANAGEMENT

Orientation towards a systemic view of the importance of maintenance business,

reassessing the use of technical and financial indicators.
Implementation of financial indicators in maintenance management as : Balanced
Scorecard (which examines the strategy into four perspectives: customer, internal
business, innovation and learning and financial perspective), Economic Value Added
(difference between return on assets and the cost of financing), Return of
Investment (return on money spent) and Economic Value Return on Capital Employed
(Edvita).

The company should consider periodic review of its objectives and goals through
innovation in processes and business activities using strategies such as
Continuous Improvement, Reengineering and Benchmarking.
LAS MEJORES EMPRESAS DE COLOMBIA Y EL MUNDO