Maintenance
Planning &
Scheduling
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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
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occurrence.
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.
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•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.
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•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.
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The Maintenance Organization:
An Introduction
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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.
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• 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.
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• Reliability:
The probability that equipment or an
asset will perform its designed function
without a failure for a period of time under
specific condition.
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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.
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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.
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Types of Maintenance
• Breakdown Maintenance.
• Preventive Maintenance (PM).
• Predictive Maintenance (PDM).
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Types of Maintenance
• Breakdown Maintenance.
• Preventive Maintenance (PM).
• Predictive Maintenance (PDM).
OR
• Reactive Maintenance
• Proactive Maintenance
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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
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Maintenance Engineering
• Maintenance Engineers work on
– design specifications of minor modifications,
– preventive maintenance documentation,
– problem identification and elimination,
– maintenance training, and
– maintenance technical database.
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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"
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• 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.
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– 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.
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• 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.
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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
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• 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.
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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.
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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.
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Integrated Planned Maintenance
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•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.
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