Maintenance Planning & Scheduling. Dr. Khaleel Abushgair

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1 Maintenance Planning & Scheduling 1

2 This course aims to train the participants on the different types of maintenance philosophies. Classification of failure will be tackled with its expected causes. The course also targets the correct diagnosis of the failure modes based on the FEMEA analysis. Moreover, the course targets the risk based maintenance and the associated activities prior to the machinery failure occurrence.

3 At the end of this course, the participants will be acquainted with the new and developed techniques that are obeyed in conjunction with the machinery failure analysis and maintenance issues. They will be quite ready to analyze the fault and identifying its cause. The participants will understand the different types of maintenance strategies and will study the maintenance direct and indirect costs with the machine life time. 3

4 In the end of the course participants should be able to: Identify the responsibilities of the maintenance personal. Describe and explain maintenance in terms of inputs, outputs, processes, information flows, and relations with its internal and external environments. Explain terminologies and philosophies related to maintenance engineering and management. Describe and use terminologies, methodologies, and tools related to maintenance subjects systematically. Distinguish between breakdown, preventive, and predictive maintenance.

5 Understand and develop best practices in maintenance. Relate reliability to maintenance. Introduce participants to software applications in the fields of maintenance engineering, reliability, and maintenance planning and scheduling. Learn preventive and predictive maintenance techniques and practices for various systems. Practice teamwork and project management skills Communicate with the industry and collect field data acquainted with the new and developed techniques that are obeyed in conjunction with the machinery failure analysis and maintenance issues Familiar with the correct diagnosis of the failure modes based on the FEMEA analysis.

6 The Maintenance Organization: An Introduction 6

7 Maintenance Management Maintenance: It is the act of holding or keeping asset in a preserved state. Asset : A machine, building or a system. It is the basic unit of maintenance. 7

8 Management: It is the act of controlling or coping with any problem. Maintenance Management: It is the act of controlling the operations of keeping an asset in a preserved state. 8

9 Reliability: The probability that equipment or an asset will perform its designed function without a failure for a period of time under specific condition. 9

10 What is the mission of maintenance? The mission of maintenance department is to provide reliable physical assets and excellent support for its customers by reducing and eventually eliminating the need for maintenance services. 10

11 Maintenance To keep in its existing state. To preserve. To continue in good operating condition. To protect. Maintenance consists of Corrective maintenance, Preventive maintenance (PM), and continuous improvement. 11

12 Types of Maintenance Breakdown Maintenance. Preventive Maintenance (PM). Predictive Maintenance (PDM). 12

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14 Types of Maintenance Breakdown Maintenance. Preventive Maintenance (PM). Predictive Maintenance (PDM). OR Reactive Maintenance Proactive Maintenance 14

15 Preventive Maintenance (PM) All actions performed to prevent failures. Lubrication, alignment, balancing, installation and equipment design, operating procedures, detailed cleaning, adjustments, fixed time replacements, and filtration. Note: Maintenance prevention and condition monitoring are the two components of preventive maintenance 15

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19 Maintenance Engineering Maintenance Engineers work on design specifications of minor modifications, preventive maintenance documentation, problem identification and elimination, maintenance training, and maintenance technical database. 19

20 Reactive and Proactive Maintenance Reactive maintenance (Repair): Fix it when it breaks. Proactive maintenance: Actions that are planned, scheduled and executed before a break-down occurs. Includes maintenance prevention activities. "Proactive Maintenance is the Mission" 20

21 Maintenance Skills Training Determine what the training is meant to accomplish. Performing a Job Task Analysis (JTA) will help you define the skill levels required of maintenance department employees. The JTA should be followed with a Skills Assessment of employee knowledge and skill levels. 21

22 Analyze the gap between required skills and available skills to determine the amount and level of training necessary to close the gap. Instituting a qualification and certification program that is set up to measure skills achievement through written exams and practical skills demonstration will provide you with feedback on training effectiveness. It will also assist in resource allocation when scheduling planned/preventive maintenance tasks. 22

23 Preventive Maintenance Tasks/Procedures Development of maintenance task documentation is one of the most time consuming requirements of the proactive maintenance approach, unless you already have in-place the written procedures that will be used to accomplish maintenance. Procedural documentation should include standardized listings of parts, material and consumable requirements, it should identify the craft and skill level(s) required to perform the task, and a frequency (or operating time based period) of performance. 23

24 Categories of maintenance procedures that will be included in planned maintenance documentation include: Routine Preventive Maintenance (lube, clean, inspect, minor component replacement, etc.) Proactive replacements (entire equipment or major component - time based or operating hours) Scheduled rebuilds or overhauls Predictive Maintenance Condition Monitoring /Performance Based Maintenance 24

25 Maintenance Engineering Development A Maintenance Engineering section should be established in the facility. The functions and responsibilities of new or existing maintenance engineering groups should be reviewed and revised to integrate and enhance the proactive maintenance organization. Finding the reasons for self-induced failures, and all failures, is a responsibility of maintenance engineering. 25

26 Why do we need to manage maintenance? It takes time. It requires materials, location, tools, equipment, and people. It affects functionality and safety. It costs money. Management is forever. 26

27 Maintenance Management is the collective term for describing the management process of leadership and organization, planning and scheduling, preventive maintenance, condition monitoring, execution of maintenance repairs, recording, root cause failure analysis, spare parts management, and management of technical data supporting the processes above. 27

28 Integrated Planned Maintenance 28

29 Internal Administrative Structure of the Maintenance Department The maintenance department can be structured in one of the following ways: By trades ( mechanical, electrical, etc) By types of service (inspection, repairs, lubrications, etc.) By areas of equipment By maintenance policy type (emergency, preventive, predictive) The internal organization structure is often a mixture of the above types. 29

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