Maintenance Cost
By Herman Saputro
Types of Maintenance
MAINTENANCE
PLANNED UNPLANNED
MAINTENANCE MAINTENANCE
(PROACTIVE) (REACTIVE)
EMERGENCY BREAKDOWN
PREDECTIVE PREVENTIVE IMPROVEMENT CORRECTIVE
MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE
STATISTICAL CONDITION - DEFERRED REMEDIAL
ENGINEERING DESIGN - OUT
- BASED BASED
SERVICES
Shutdown Maintenance
WINDOW RUNNING ROUTINE OPPORTU- SHUTDOWN SHUTDOWN SHUTDOWN
NITY PREVENTIVE IMPROVEMENT CORRECTIVE
Figure Maintenance Types
Types of Maintenance
• Run to Failure Maintenance (RTF)
• Preventive Maintenance (PM)
• Corrective Maintenance (CM)
• Improvement Maintenance (IM)
• Predictive Maintenance (PDM)
Run to Failure Maintenance (RTF)
• The required repair, replacement, or restore action
performed on a machine or a facility after the
occurrence of a failure in order to bring this
machine or facility to at least its minimum
acceptable condition.
• It is the oldest type of maintenance.
Run to Failure Maintenance (RTF)
• It is subdivided into two types:
– Emergency maintenance: it is carried out as fast
as possible in order to bring a failed machine or
facility to a safe and operationally efficient
condition.
– Breakdown maintenance: it is performed after
the occurrence of an advanced considered failure
for which advanced provision has been made in
the form of repair method, spares, materials,
labour and equipment.
Run to Failure Maintenance (RTF)
• Disadvantages:
1. Its activities are expensive in terms of both direct and
indirect cost.
2. Using this type of maintenance, the occurrence of a failure
in a component can cause failures in other components in
the same equipment, which leads to low production
availability.
3. Its activities are very difficult to plan and schedule in
advance.
Run to Failure Maintenance (RTF)
• This type of maintenance is useful in the following
situations:
1. The failure of a component in a system is unpredictable.
2. The cost of performing run to failure maintenance activities
is lower than performing other activities of other types of
maintenance.
3. The equipment failure priority is too low in order to include
the activities of preventing it within the planned
maintenance budget.
Preventive Maintenance (PM)
It is a set of activities that are performed on plant
equipment, machinery, and systems before the
occurrence of a failure in order to protect them and
to prevent or eliminate any degradation in their
operating conditions.
Preventive Maintenance (PM)
British Standard 3811:1993 Glossary of terms
defined preventive maintenance as:
the maintenance carried out at predetermined
intervals or according to prescribed criteria and
intended to reduce the probability of failure or the
degradation of the functioning and the effects
limited.
Preventive Maintenance (PM)
• The advantage of applying preventive maintenance
activities is to satisfy most of maintenance
objectives.
Preventive Maintenance (PM)
• The factors that affect the efficiency of this type of maintenance:
1. The need for an adequate number of staff in the maintenance
department in order to perform this type of maintenance.
2. The right choice of production equipment and machinery that is
suitable for the working environment and that can tolerate the
workload of this environment.
3. The required staff qualifications and skills, which can be gained
through training.
4. The support and commitment from executive management to the
PM programme.
5. The proper planning and scheduling of PM programme.
6. The ability to properly apply the PM programme.
Preventive Maintenance (PM)
• It is good for those machines and facilities which
their failure would cause serious production losses.
• Its aim is to maintain machines and facilities in
such a condition that breakdowns and emergency
repairs are minimised.
• Its activities include replacements, adjustments,
major overhauls, inspections and lubrications.
Preventive Maintenance (PM)
• Researchers subdivided preventive maintenance into
different kinds according to the nature of its activities:
• Routine maintenance which includes those maintenance
activities that are repetitive and periodic in nature such as
lubrication, cleaning, and small adjustment.
• Running maintenance which includes those maintenance
activities that are carried out while the machine or
equipment is running and they represent those activities that
are performed before the actual preventive maintenance
activities take place.
Preventive Maintenance (PM)
• Opportunity maintenance which is a set of maintenance
activities that are performed on a machine or a facility when
an unplanned opportunity exists during the period of
performing planned maintenance activities to other machines
or facilities.
• Window maintenance which is a set of activities that are
carried out when a machine or equipment is not required for
a definite period of time.
• Shutdown preventive maintenance, which is a set of
preventive maintenance activities that are carried out when
the production line is in total stoppage situation.
Corrective Maintenance (CM)
• In this type, actions such as repair, replacement, or
restore will be carried out after the occurrence of a
failure in order to eliminate the source of this
failure or reduce the frequency of its occurrence.
In the British Standard 3811:1993 Glossary of terms,
corrective maintenance is defined as:
the maintenance carried out after recognition and intended to
put an item into a state in which it can perform a required
function.
Corrective Maintenance (CM)
• This type of maintenance is subdivided into three
types:
• Remedial maintenance, which is a set of activities
that are performed to eliminate the source of failure
without interrupting the continuity of the
production process.
The way to carry out this type of corrective maintenance is
by taking the item to be corrected out of the production line
and replacing it with reconditioned item or transferring its
workload to its redundancy.
Corrective Maintenance (CM)
• Deferred maintenance, which is a set of corrective
maintenance activities that are not immediately
initiated after the occurrence of a failure but are
delayed in such a way that will not affect the
production process.
• Shutdown corrective maintenance, which is a set of
corrective maintenance activities that are performed
when the production line is in total stoppage
situation.
Corrective Maintenance (CM)
• The main objectives of corrective maintenance are the
maximisation of the effectiveness of all critical plant
systems, the elimination of breakdowns, the elimination of
unnecessary repair, and the reduction of the deviations from
optimum operating conditions.
• The difference between corrective maintenance and
preventive maintenance is that for the corrective
maintenance, the failure should occur before any corrective
action is taken.
• Corrective maintenance is different from run to failure
maintenance in that its activities are planned and regularly
taken out to keep plant’s machines and equipment in
optimum operating condition.
Corrective Maintenance (CM)
• The way to perform corrective maintenance activities is by
conducting four important steps:
1. Fault detection.
2. Fault isolation.
3. Fault elimination.
4. Verification of fault elimination.
In the fault elimination step several actions could be taken
such as adjusting, aligning, calibrating, reworking,
removing, replacing or renovation.
Corrective Maintenance (CM)
• Corrective maintenance has several prerequisites in
order to be carried out effectively:
1. Accurate identification of incipient problems.
2. Effective planning which depends on the skills of the
planners, the availability of well developed maintenance
database about standard time to repair, a complete repair
procedures, and the required labour skills, specific tools,
parts and equipment.
3. Proper repair procedures.
4. Adequate time to repair.
5. Verification of repair.
Improvement Maintenance (IM)
• It aims at reducing or eliminating entirely the need for
maintenance.
• This type of maintenance is subdivided into three types as
follows:
1. Design-out maintenance which is a set of activities that
are used to eliminate the cause of maintenance, simplify
maintenance tasks, or raise machine performance from the
maintenance point of view by redesigning those machines
and facilities which are vulnerable to frequent occurrence of
failure and their long term repair or replacement cost is very
expensive.
Improvement Maintenance (IM)
2. Engineering services which includes construction and
construction modification, removal and installation, and
rearrangement of facilities.
3. Shutdown improvement maintenance, which is a set of
improvement maintenance activities that are performed
while the production line is in a complete stoppage situation.
Predictive Maintenance (PDM)
• Predictive maintenance is a set of activities that detect
changes in the physical condition of equipment (signs of
failure) in order to carry out the appropriate maintenance
work for maximising the service life of equipment without
increasing the risk of failure.
• It is classified into two kinds according to the methods of
detecting the signs of failure:
– Condition-based predictive maintenance
– Statistical-based predictive maintenance
Predictive Maintenance (PDM)
• Condition-based predictive maintenance depends on
continuous or periodic condition monitoring equipment to
detect the signs of failure.
• Statistical-based predictive maintenance depends on
statistical data from the meticulous recording of the
stoppages of the in-plant items and components in order to
develop models for predicting failures.
Predictive Maintenance (PDM)
• The drawback of predictive maintenance is that it depends
heavily on information and the correct interpretation of the
information.
• Some researchers classified predictive maintenance as a type
of preventive maintenance.
• The main difference between preventive maintenance and
predictive maintenance is that predictive maintenance uses
monitoring the condition of machines or equipment to
determine the actual mean time to failure whereas
preventive maintenance depends on industrial average life
statistics.
Maintenance Cost
Total Cost
Preventive
maintenance
cost
Maintenance cost (RM)
Breakdown
maintenance
cost
Optimum
Cost of Maintenance
Spare parts •
Labor •
Down time (production loss) •
Overhead •
Consumables •
Hand tools, power tools and equipment •
Who will do maintenance?
In-house •
Out-source •
Decision to out-source
Lack of expertise •
Too hazardous •
No experience •
Bound by contract •
Top management policy •
Example
The record of computer breakdown for
Company PCK for the past 20 months is
shown below.
# of breakdown # of months breakdown occurs
0 4
1 8
2 6
3 2
Total 20
Each time computer breakdown – •
estimated loss is RM300
Contract preventive maintenance by •
company DK – RM200 per month
Should PCK contract out preventive •
maintenance to DK?
Solution
Step 1
Calculate expected number of breakdown •
(based on past records) if the company continue
without service contract.
Step 2
Compute expected breakdown cost per month •
with no preventive maintenance contract
Step 3
Compute the cost of preventive maintenance •
Solution
Step 4
Compare the two options and select the •
one which cost less
Solution
# of breakdown Frequency
0 4/20 = 0.2
1 8/20 = 0.4
2 6/20 = 0.3
3 2/20 = 0.1
Step 1
Expected # of breakdowns = (# of breakdown) x (frequency)
= (0)(0.2)+(1)(0.4)+(2)(0.3)+(3)(0.1)
= 1.3 breakdown per month
Solution
Step 2
Expected breakdown cost = (expected # of breakdown) x
(cost per breakdown)
= (1.3) x (300)
= RM390 per month
Solution
Step 3 Calculate Preventive Maintenance Cost
= cost of expected breakdown + cost of service contract
= (1 breakdown per month x 300) + RM220 per month
= RM520 per month
Step 4 Compare
Less expensive to suffer breakdown without service contract.
Breakdown = RM390
Service contract = RM520
Therefore, continue present policy.
Need to consider
Customer service •
Loss of production •
Loss of customer goodwill, reputation •
Machine life •
Availability of spare parts and expertise •
Safety to the user / customer •
Environmental problem (pollutant discharge etc.) •
Determining the Size of Repair Crews
Problem: •
A factory has 200 machines and the maintenance •
engineer supervises the repair crews who repair
malfunctioning machines. The maintenance policy is to
repair the broken down machine and bring back in
production within 2 hours on the average. If average
breakdown rate is 3.5 machines/hour and each repair
crew can repair 0.25 machine per hour on the average.
How many repair crews are required ?
Solution
The formula for average repair rate () is
1
= + 1/ ts or ts = ----------
-
Where = repair rate
= arrival rate of malfunctioning machines
ts = average time arrivals in the system
Required average repair rate
= 3.5 + 1 / 2 = 4 machines / hour
= machines/hour a crew can repair No. of Crews
= 4 0.25 = 16 repair crews required
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BAGAIMANA DENGAN MAINTENACE COST DI BENGKEL
PERMESINAN????
