Reliable Centered Maintenance
Content
RCM The RCM process described in the DOD/UAL report recognized three principal risks from equipment failures: threats
to safety, to and budget. to operations, the maintenance
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, d esign, to operations, or to other things).
Maintenance types[edit types[edit]] Generally speaking, there are three types of maintenance in use:
maintenance,, where equipment is maintained before break down occurs. This type Preventive maintenance of maintenance has many different variations and is subject of various researches to t o determine best and most efficient way to maintain equipment. Recent studies have shown that Preventive maintenance is effective in preventing age related r elated failures of the equipment. For random failure patterns which amount to 80% of the failure patterns, condition monitoring proves to be effective.
Operational maintenance, maintenance, where equipment is maintained in using. Corrective maintenance maintenance,, where equipment is maintained after break down. This maintenance is often most expensive because worn equipment can damage other ot her parts and cause multiple damages.
maintenance[[edit ] Preventive maintenance Main article: article: Preventive maintenance 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 the RCM analysis analysis which it was based on, and the ground rules used for cost-effectivity cost-effectivity..[4]
Further information: information: Planned maintenance maintenance
maintenance[edit ] Corrective maintenance[ Repair shop shop Main article: article: Corrective maintenance maintenance
Corrective maintenance is probably the most commonly commonl y 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 than preventive preventive maintenance. maintenance. Corrective maintenance is the program focused on the regular task that will maintain all the critical machinery and the system in optimum operating ope rating 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 maintenance[[edit ] Main article: article: Reliability centered maintenance 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 und erstand the working of their physical assets. This is embodied in the initial part of the the RCM process which is to identify the operating context of the machinery, machiner y, 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; pack ages; 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 software[edit]] Main article: article: MRO Software 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.
installations,, large plants This is particularly the case in aerospace (e.g. airline fleets), fleets), military installations (e.g. manufacturing, power generation, petrochemical) and ships. These software tools help engineers and technicians technicia ns in increasing the the system availability 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 with an organization’s products, resources, suppliers and customers, MRO packages have to interface with many enterprise enterprise business business software software systems (PLM, PLM, EAM EAM,, ERP, SCM, ERP, SCM, CRM CRM)). One of the functions of such software is the configuration of bills bills of materials materials or BOMs, taking the component parts list from engineering (eBOM) and manufacturing man ufacturing (mBOM) and updating it from "as designed― through "as built‖, "as delivered", ―as maintained‖, and ―as used‖. used‖. Another function is project planning planning logistics, logistics, for example identifying the the critical path path on the list of tasks to be carried out (inspection, diagnosis, dia gnosis, 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: Maintenance service history, o Serial numbered numbered parts, o Reliability data: data: MTBF MTBF,, MTTB (mean time to breakdown), MTBR (mean time t ime between o removals), Maintenance and repair documentation and best practices, o Warranty/guarantee documents. o
systems (CMMS). Many of these tasks are addressed in in computerized maintenance management systems Data standards have been developed around these activities, most notably notably EAMXML EAMXML and MIMOSA. MIMOSA. What is the de defi fi niti on of " autonomous maintenance 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. parts. Learn more about autonomous maintenance in maintenance in the class Total Productive Maintenance Overview 150 below.
autonomous maintenance maintenance
Maintenance that is performed by the machine operator rather than the maintenance staff. Autonomous maintenance includes in cludes tasks such as lubricating and tightening machine parts.
availability availability
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.
condition basic condition
The expected good state of repair r epair 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.
breakdown maintenance maintenance
Maintenance performed on broken machines to restore them to working order.
cell cell
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 certification
Certification be awarded by body. a school, a professional organization,may or other governing
continuous improvement improvement
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 satis fy customers.
downtime downtime
The period of time when a machine or a factory is not operating and is not producing.
external customer
An outside organization or individual that receives a product or service from the company.
finishing finishing
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.
S Five S
A targeted list of activities that promotes organization and efficiency within a workspace. The Five S terms are sifting, sorting, sweeping, standardizing, and sustaining.
internal customer
A department or individual within the company that relies on others to satisfy the external customer.
Standardization ISO. An organization based in Switzerland that develops and International Organization for Standardization
publishes standards for its international membership base.
kaizen kaizen
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
event kaizen event
departments to examine a problem, propose solutions, and implement changes. Kaizen events usually take place over one or two days.
lean lean
An approach to manufacturing that seeks to improve product quality and productivity, reduce cost, and eliminate waste.
maintenance maintenance
The necessary and basic support and repair of machines. Maintenance includes tasks such as lubricating, adjusting, adj usting, and replacing parts.
prevention maintenance prevention
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.
TPM office TPM
Application of the principles of total productive maintenance to the administrative areas of the company.
overall equipment effectiveness effectiveness
OEE. The percentage of equipment's availability, quality, and performance multiplied together.
rate performance rate
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 periodic maintenance
Maintenance performed on a calendar basis.
planned maintenance maintenance
Maintenance that is performed purposely and regularly in order to prevent a machine from deteriorating or breaking down.
maintenance predictive maintenance
Maintenance performed based on the known and expected behavior, condition, and history of the machine.
maintenance preventive maintenance
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.
pull system system
A material management system in which parts are not delivered to machines until they are needed. Pull P ull systems place demands on
maintenance to keep machines up and running.
quality quality
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 quality maintenance
Maintenance focusing on tasks that keep machines producing prod ucing quality, error-free parts.
quality rate rate
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.
safety safety
The practices and policies that a company puts in place in order to preserve the health and well-being of employees, equipment, and facilities.
losses six big losses
Areas in manufacturing where the greatest amounts of materials and time are wasted. They include breakdowns, setup and adjustment time, idling losses. and minor stoppages, speed reduction, quality defects, and startup
total productive maintenance maintenance
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.
Autonomous Maintenance Autonomous Maintenance What is Autonomous Maintenance? Autonomous Maintenance Autonomous Maintenance is the second second of the the eight pillars pillars of TPM. It follows a structured approac approach h 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] Engineering edit]
Road repair estate and and engineering engineering in general, the term maintenance In In telecommunication, telecommunication, commercial real estate has the following meanings: 1. Any activity – activity – such such as tests, measurements, replacements, adjustments and repairs — repairs — intended to retain or restore a a functional unit unit in or to a specified state in which the unit can perform its required functions. functions.[3] 2. For material — material — all all action taken to retain material ma terial in a serviceable condition or to restore it to serviceability. It includes inspection, testing, servicing, classification as to [3] serviceability, repair, repair, rebuilding, rebuilding, and reclamation. reclamation. 3. For material — material — all all supply and repair action taken to keep a force in condition to carry out [3] its mission. mission. 4. For material — material — the the routine recurring work required to keep a facility ( plant, plant, building, structure, ground structure, ground facility, utility utility system, system, or other real property) in such condition that it may be continuously used, at its original or designed design ed capacity and efficiency for its [3] intended purpose. purpose. Manufacturers and Industrial Supply Companies often refer to MRO as opposed o pposed to Original Equipment Manufacturer (OEM) 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.
