Maintenance Management

BE-7120 Reliability based decision support system for the maintenance management of the underaround networks of utilities. Prof. T. Hadailacos Computer Tech. Instrtute Patras Uniwerirty... 

Maintenance managers should be on board during the design state to ensure the maintainabiUty of a faciUty. A maintenance manager s case is simple the original cost of new constmction is soon forgotten, but faciUty maintenance and operational costs continue for the life of a faciUty. 

In selecting a suppHer or manufacturer, the maintenance manager must be sure that the suppHer can provide the support needed to operate and maintain the faciUty effectively. The suppHer or manufacturer must be willing and able to service the faciHty in the future, to instmct and oversee installation, and to provide adequate maintenance instmctions and training. Also, parts must be readily available and locally stocked. 

Maintenance costs influence the bottom line of every balance sheet. As a result, maintenance managers can improve the entire faciHty by helping make sure that the planning and design of new constmction and renovation projects takes place with maintenance in mind (1). 

In order to estabUsh this type of service, the maintenance management should meet often with their outside suppHer as weU as with their iaside customers to benefit the end user the external customers. During these meetings the foUowiag steps should be taken to assure nonstop quahty Hsten to the customers, work with customers to clarify expectations, identify measurable iadicators, exceed expectations, deUver products and services when customers need them, keep promises, design for ease of use, constandy improve, focus improvements on areas related to customer expectations, and respond quickly (5). 

The American lastitute of Plant Engineers, Cincinnati, Ohio, pubUshes an information services catalog which features Facility Management Eibrary Eeprint Services.Qs. H. Magee, Facilities Maintenance Management, R. S. Means, Kingston, Mass., 1988. 

Industrial soHd waste Inventory Maintenance Management scheduling Material safety data sheets... 

It is not uncommon to hear the complaint that the maintenance department has never been informed as to what is happening in the plant. If this is a common complaint, the maintenance manager needs to examine the communications in his department. The following are six practical suggestions for improving communications ... 

This element covers preventive maintenance, management of change (process change control) and verification practices, and frequencies for quality... 

The plant engineer and his maintenance manager will establish whoever carries out the work, basic strategy, programming and procedures. Inspection checklists and record sheets are necessary for systematic location of critical elements/potential defects and setting out frequencies of inspection. Computers and work processors are an obvious aid to effective maintenance management. Inspection-based preventive methods are demonstrably cost effective. 

The fact that vibration profiles can be obtained for all machinery having rotating or moving elements allows vibration-based analysis techniques to be used for predictive maintenance. Vibration analysis is one of several predictive maintenance techniques used to monitor and analyze critical machines, equipment, and systems in a typical plant. However, as indicated before, the use of vibration analysis to monitor rotating machinery to detect budding problems and to head off catastrophic failure is the dominant predictive maintenance technique used with maintenance management programs. 

Recent surveys of maintenance management effectiveness indicate that one-third, 33 cents out of every dollar, of all maintenance costs is wasted as the result of unnecessary or improperly carried out maintenance. When you consider that US industry spends more than 200 billion dollars each year on maintenance of plant equipment and facilities, the impact on productivity and profit that is represented by the maintenance operation become clear. 

The result of ineffective maintenance management represents a loss of more than 60 billion dollars each year. Perhaps more important is the fact that our ineffective management of maintenance dramatically impacts our ability to manufacture quality products that are competitive in the world market. The loss of production time and product quality that results from poor or inadequate maintenance management has had a dramatic impact on our ability to compete with Japan and other countries that have implemented more advanced manufacturing and maintenance management philosophies. 

Predictive maintenance is not a substitute for the more traditional maintenance management methods. It is, however, a valuable addition to a comprehensive, total plant maintenance program. Where traditional maintenance management programs rely on routine... 

Several other benefits can be derived from a viable predictive maintenance management program verification of new equipment condition, verification of repairs and rebuild work and product quality improvement. 

The overall benefits of predictive maintenance management have proven to substantially improve the overall operation of both manufacturing and process plants. In all surveyed cases, the benefits derived from using condition-based management have offset the capital equipment cost required to implement the program within the first three months. Use of microprocessor-based predictive maintenance techniques has further reduced the annual operating... 

Vibration analysis is the dominant technique used for predictive maintenance management. Since the greatest population of typical plant equipment is mechanical, this technique has the widest application and benefits in a total plant program. This technique uses the noise or vibration created by mechanical equipment and in some cases by plant systems to determine their actual condition. 

The labor-intensive part of predictive maintenance management is complete. A viable program has been established, the database is complete and you have begun to monitor the operating condition of your critical plant equipment. Now what ... 

Evolution of standards Labor standards used for maintenance management and control are relatively new in concept. Although labor standards have been used in production with ever-increasing application since late in the nineteenth century, serious application to maintenance probably dates back to someplace between 1940 and 1950. While the tools and techniques are in existence today, the application is still probably minor when compared to the potential. As a matter of fact most maintenance controls today are based on elementary management concepts, such as estimates or historical averages. 

This chapter examines the need for lubrication and the types of lubricant available. Various applications are considered, including engines gears, hydraulic equipment, machine tools, metal cutting and working fluids, compressors, turbines and electrical oils. The care of lubricants on-site, application of planned lubrication and inclusion within overall maintenance management are examined. 

A few computerized PLM schemes are dynamic systems and can be integrated into an overall maintenance management information system. These contain maintenance inventory and purchase order modules and go far beyond just another work order system . They provide the necessary information to control complex maintenance environments, thereby improving productivity and reducing operational costs. 

---