CM 3355 Module 6
Maintenance Schedule
- a list of planned maintenance tasks to be performed during a given time period, together with the expected start times and durations of each of these tasks. Schedules can apply to different time periods (e.g. Daily Schedule, Weekly Schedule etc.)
Unscheduled Maintenance
- any maintenance work that has not been included on an approved Maintenance Schedule prior to its commencement
Reliability
- the capability of an asset to continue to perform its intended functions. Normally measured by Mean Time Between Failures
Emergency Work
- unscheduled work that requires immediate attention
KPI = Key Performance Indicators
A select number of key measures that enable performance against targets to be monitored
RCM = Reliability Centered Maintenance
A structured process, originally developed in the airline industry, but now commonly used in all industries to determine the equipment maintenance strategies required for any physical asset to ensure that it continues to fulfil its intended functions in its present operating context. A number of books have been written on the subject, but none better than Moubray's book, RCM II
Non-routine Maintenance
Any maintenance task which is not performed at a regular, predetermined frequency
Inspection
Any task undertaken to determine the condition of equipment, and/or to determine the tools, labor, materials, and equipment required to repair the item
Proactive Maintenance
Any tasks used to predict or prevent equipment failures
This maintenance craft job description includes - Constructing, erecting, installing, fabricating, dismantling and repairing structures, formwork and fixtures of wood, metal forms, and associated accessories:
Carpenter
Benefits of a preventive maintenance program include:
Decreased equipment downtime and major repairs. Increased equipment life expectancy, eliminating premature equipment replacement. Reduced overtime costs due to employees working on a schedule as opposed to an emergency basis to attend to repairs and breakdowns. Reduction in large-scale repairs. Improved safety and conditions for employees.
The main objectives of preventive maintenance are as follows:
Enhance asset/equipment productive life. Reduce critical equipment breakdowns. Minimize production loss due to equipment failures
This maintenance craft job description includes - Raising, placing and uniting girders, columns and other structural-steel members to form completed structure frameworks:
Ironworker
Any activity carried out on an asset to ensure that the asset continues to perform its intended functions or to repair the equipment:
Maintenance
Shutdown Maintenance
Maintenance that can only be performed while equipment is shutdown
Designed to help determine the condition of in-service equipment to indicate in advance when maintenance should be performed:
Predictive Maintenance
The care and servicing by personnel to maintain equipment and facilities in satisfactory operating condition by providing for systematic inspection, detection, and correction of failures either before they occur or before they develop into significant defects:
Preventive Maintenance
The capability of an asset to continue to perform its intended functions. Normally measured by mean time between failures.
Reliability
Generally used to achieve improvements in fields such as the establishment of safe minimum levels of maintenance, changes to operating procedures and strategies, and the establishment of capital maintenance regimes and plans:
Reliability Centered Maintenance
The 3 Elements of Preventative Maintenance
Systematic Performed routinely Aimed at reducing or minimizing failures
Purchase Order
The prime document raised by an organization, and issued to an external supplier, ordering specific materials, parts, supplies, equipment or services
Purchase Requisition
The prime document raised by user departments authorizing the purchase of specific materials, parts, supplies, equipment or services from external suppliers
Work Order
The prime document used by the maintenance function to manage maintenance tasks. It may include such information as a description of the work required, the task priority, the job procedure to be followed, the parts, materials, tools and equipment required to complete the job, the labor hours, costs and materials consumed in completing the task, as well as key information on failure causes, what work was performed etc
Backlog
Work which has not been completed by the nominated 'required by date'. The period for which each Work Order is overdue is defined as the difference between the current date and the 'required by date'. All work for which no 'required by' date has been specified is generally included on the backlog. Backlog is generally measured in "crew-weeks", that is, the total number of labor hours represented by the work on the backlog, divided by the number of labor hours available to be worked in an average week by the work crew responsible for completing this work. As such, it is one of the common Key Performance Indicators used in maintenance.
Scheduled Work Order
a Work Order that has been planned and included on an approved Maintenance Schedule
TPM = Total Productive Maintenance
a company-wide equipment management program, with its origins in Japan, emphasizing production operator involvement in equipment maintenance, and continuous improvement approaches
CMMS = Computerized Maintenance Management System
a computerized system to assist with the effective and efficient management of maintenance activities through the application of computer technology. It generally includes elements such as a computerized Work Order system, as well as facilities for scheduling Routine Maintenance Tasks, and recording and storing Standard Jobs, Bills of Materials and Applications Parts Lists, as well as numerous other features
BOM = Bill of Materials
a list of all the parts and components that make up a particular asset. Not to be confused with an Applications Parts List
Maintenance Strategy
a long-term plan, covering all aspects of maintenance management which sets the direction for maintenance management, and contains firm action plans for achieving a desired future state for the maintenance function
Emergency Maintenance Task
a maintenance task carried out in order to avert an immediate safety or environmental hazard, or to correct a failure with significant economic impact
Best Practice
a practice that is internal or external to the company or industry, that represents the best way to accomplish work
Breakdown
a specific type of failure, where an item of plant or equipment is completely unable to function
Outage
a term used in some industries (notably power generation) which is equivalent to a shutdown
Apprentice
a tradesperson (or craftsperson) in training
Tradesperson
alternative to craftsperson. A skilled maintenance worker who has typically been formally trained through an apprenticeship program
Craftsperson
alternative to tradesperson. A skilled maintenance worker who has typically been formally trained through an apprenticeship program
CBM = Condition Based Maintenance
an equipment maintenance strategy based on measuring the condition of equipment in order to assess whether it will fail during some future period, and then taking appropriate action to avoid the consequences of that failure. The condition of equipment could be monitored using Condition Monitoring, Statistical Process Control techniques, by monitoring equipment performance, or through the use of the Human Senses. The terms Condition Based Maintenance, On-Condition Maintenance and Predictive Maintenance can be used interchangeably
PM = Preventive Maintenance
an equipment maintenance strategy based on replacing, overhauling or remanufacturing an item at a fixed interval, regardless of its condition at the time
Failure
an item of equipment has suffered a failure when it is no longer capable of fulfilling one or more of its intended functions. Note that an item does not need to be completely unable to function to have suffered a failure. For example, a pump that is still operating, but is not capable of pumping the required flow rate, has failed. In Reliability Centered Maintenance terminology, a failure is often called a Functional Failure. Would you classify a planned equipment shutdown as a failure? Would you classify a routine equipment shutdown at shift change as a failure? Under this definition, the answer in the first case would be yes, but in the second case would be no. The justification for the inclusion of planned shutdowns as failures is that a failure, as defined, causes a disruption to the desired steady-state nature of the production process, and therefore should, ideally, be avoided
Maintenance
any activity carried out on an asset in order to ensure that the asset continues to perform its intended functions, or to repair the equipment. Note that modifications are not maintenance, even though they may be carried out by maintenance personnel
Modification
any activity carried out on an asset which increases the capability of that asset to perform its required functions.
Planned Maintenance
any maintenance activity for which a pre-determined job procedure has been documented, for which all labor, materials, tools, and equipment required to carry out the task have been estimated, and their availability assured before commencement of the task
Unplanned Maintenance
any maintenance activity for which a pre-determined job procedure has not been documented, or for which all labor, materials, tools, and equipment required to carry out the task have been not been estimated, and their availability assured before commencement of the task
Routine Maintenance Task
any maintenance task that is performed at a regular, predefined interval
Scheduled Maintenance
any maintenance work that has been planned and included on an approved Maintenance Schedule
Maintenance Work Flow
covers all aspects of work management such as, requesting, approving, planning, scheduling, completion and documentation of maintenance activities
Average Life
how long, on average, a component will last before it suffers a failure. Commonly measured by Mean Time Between Failures
Root Cause Analysis (RCA) -
is a systematic process whereby failures are analyzed, usually by a cause and effect methodology, to determine the underlying root causes
Prescriptive maintenance
it leverages machine-learning software - artificial intelligence (AI) and the internet of things (IoT) connectivity - to help schedule preventive maintenance tasks
Schedule Compliance
one of the Key Performance Indicators often used to monitor and control maintenance. It is defined as the number of Scheduled Work Orders completed in a given time period (normally one week), divided by the total number of Scheduled Work Orders that should have been completed during that period, according to the approved Maintenance Schedule for that period. It is normally expressed as a percentage, and will always be less than or equal to 100%. The closer to 100%, the better the performance for that time period
NDT = Non-Destructive Testing
testing of equipment, which does not destroy the equipment, to detect abnormalities in physical, chemical or electrical characteristics. Techniques which are considered to be NDT techniques are ultrasonic thickness testing, dye penetrant testing, xraying, and electrical resistance testing
Shutdown
that period of time when equipment is out of service
Maintainability
the ease and speed with which any maintenance activity can be carried out on an item of equipment. May be measured by Mean Time to Repair. Is a function of equipment design, and maintenance task design (including use of appropriate tools, jigs, work platforms etc.)
Benchmarking
the process of comparing performance with other organizations, identifying comparatively high-performance organizations and learning what it is they do that allows them to achieve that high level of performance
Priority
the relative importance of a task in relation to other tasks. Used in scheduling work orders
Asset Management
the systematic planning and control of a physical resource throughout its life. This may include the asset's specification, design, and construction of the asset, its operation, maintenance, and modification while in use, and disposal when no longer required.
Downtime
the time that an item of equipment is out of service, as a result of equipment failure. The time that an item of equipment is available, but not utilized is generally not included in the calculation of downtime.
Available Hours
the total number of hours that an item of equipment is capable of performing its specified functions. It is equal to the total hours in any given period, less the downtime hours.
Asset
unlike in the accounting definition, in maintenance, this is commonly taken as any item of physical plant or equipment.
Reactive Maintenance
unplanned maintenance activities; usually performed in response to an equipment failure
Predictive maintenance
used with Computerized Maintenance Management Systems (CMMS) software. Logging work order data into a CMMS lets managers review data and notice patterns in breakdowns over time. This information enables managers to predict when downtime will occur based on historical data and schedule maintenance tasks to prevent it