welcome to atf205 introduction to modern maintenance practices ► dr david baglee ►...
TRANSCRIPT
Welcome to ATF205Introduction to Modern Maintenance
Practices
► Dr David Baglee► [email protected]► Phone: 515 2869► http://osiris.sunderland.ac.uk/~cs0dba/
AMAP The Industry Centre Wessington Way
► Thursday 1pm-5pm (including project management)
► Lectures and lab. ► Two assignments
Maintenance and Asset Management Links
► http://www.skf.com/aptitudexchange/glossary.html► http://www.reliabilityweb.com► http://www.reliabilityweb.com/excerpts/► http://www.maintenanceresources.com► http://www.maintenanceworld.com► http://www.plant-maintenance.com► http://www.mt-online.com► http://www.cmmscity.com/articles/
cmms_articles.htm
Maintenance Spending
► Europe €120 Billion Annual Spend Employs 2 million people
► United Kingdom £16 Billion Annual Spend Employs ?
No records indicate reactive maintenance spending
Trends
► Assets Assets must run longer Impact of asset failure can be very large
► Expertise Downsizing and aging workforce has caused ‘skill
gap’ at plant sites Technology is evolving faster than it can be adopted
► Working Practices Asset management is moving from reactive to
proactive Abnormal situation management procedures are
improving operations effectiveness
Recent Events
► Tube Crash - Chancery Lane, London Bolts holding motor failed, train derailed 30 hurt. £ms
lost
► Electricity Supply Failure - USA, Italy, UK► Rail Crash - Hatfield, UK
4 people died: lack of maintenance on lines
► Concorde Crash - CdG Airport, Paris► BP Refinery Explosion, Texas
Vent system not maintained $ms damage loss of life
► Food contamination at Cadburys: Unchecked pipe during maintenance leaked oil, 75’000
bars recalled
Example: Car Maintenance
►What must be done to maintain your car? Change the oil every 6,000 miles Check and/or change air filter Check and/or change hoses and belts Clean inside/wash outside Replace brake pads Regular inspection
Maintenance Strategies
► Run-to-fail► Time based► Condition Based
►Modern Maintenance Reliability Centred Maintenance (RCM) Total Productive Maintenance (TPM) Condition Based Maintenance (CBM)
Period between 1900-Present
Characteristics of equipment Maintenance philosophy
First generation maintenance
(1900-1939)
Equipment is simple and easy to repair
Basic and routine maintenanceReactive maintenance, “only repair when broke”
Second generation maintenance
(1945-1979)
Equipment is more complex, greater dependence of industry on equipment
Maintenance costs are higher in relation to other operating costs
Planned preventive maintenanceTime based approach
Total Productive Maintenance (TPM) ‘Total' employee participation.
Team based approach to maintenance, examines “culture and people” not systems
Third generation maintenance
(1980s-present)
Equipment complexity increasingAccelerated use of automationDowntime very expensiveIncreasing use of Just-In-Time
Customers now demanding higher
quality goods
Tightening legislation on safety
Condition monitoring (CM), hazard studies, failure modes and effect analysis
Reliability centred maintenance (RCM) examines “machine and systems”
Computer aided maintenance managementMulti-skilled workforceEmphasis on equipment reliability and
availabilityMaintenance is now proactive and strategic
Example: Car Maintenance
► Implications of poor car maintenance? Premature failures Increased running costs Unexpected breakdowns Personal injury or death Government shuts you down
Barriers to maintenance strategy development
► Limited staff► Lack of training► Inadequate diagnostic equipment►Missing technical documentation► Budget issues► Inadequate monitoring of equipment ► Lack of management commitment► Poor morale
Neglected Maintenance
►Operating equipment in manual override
► Incorrectly adjusted equipment► Inefficient operations► Inoperative equipment► Steam, air, water leaks► Faulty control systems
Results of Poor Practices
► Short and Long term effects: Increased energy costs Increased major maintenance work Increased capital costs due to shortened
equipment life Continued morale degradation HEALTH & SAFETY INNAPROPRIATE TASKS
Costs Involved
► Equipment purchase► Training► Extra staff
► Costs can be insignificant when compared with cost of not improving maintenance methods
► Industry loses per year are huge due to inadequate maintenance activity
Benefits
► Improved equipment efficiency► Increased product quality► Identify equipment defects► Reduced equipment failures► Increased production► Improved safety► Minimize damage to equipment► Provide guidelines for new equipment purchase► Effectively prioritize decreasing resources► Improve staff morale
Recent Advances Equipment1.) PDA2.) Cost £2503.) Metal-on-mount ICode RFID Tags: 10p4.) USB Vibration Sensor £100
PDA Specification:WiFiBluetoothUSB HostCompact Flash Slot