Maintenance Management

Maintenance Planning & Control

October 10, 2021 1

 Maintenance Planning
Maintenance
Management
 Has To Be Balanced

Production Maintenance/Repair

October 10, 2021 Slide No 2

 Equipment Management
Maintenance
Management
 Is a positive and Key Contributor to Business Performance

 Should NOT be a Cost Burden

 Can Have a Big Impact on

 PROFITABILITY - successful PM always shows up on the bottom
line
 Capital Investment - fewer machines, lower inventories
 Infrastructure costs- facilities, tooling, inventories, etc

 Can Control and/or Prevent Failures

October 10, 2021 Slide No 3

 Establishing A Preventative Maintenance Program
Maintenance
Management

 Organizing the program

 Operating the program

Top Management

Production Maintenance
Team
Supervision Supervision
Work

Machine Operators
& Service People
(Logistics / Materials)
October 10, 2021 Slide No 4
 Equipment Management Plan
Maintenance
Management
PM
Resources Services Cost/Record
System

Condition
Scheduling Problem
Monitoring
System Management
System

Component Parts
R&I Component Management
Overhaul

October 10, 2021 Slide No 5

 Establishing Preventive Maintenance Program
Organizing Operate
Maintenance
Management List equipment to be Issue Schedules
included in program Perform Services

Develop service routes Report Results

for fixed equipment Monitor Repairs
Made

Prepare program for Check actual versus

mobile equipment planned service times

Prepare checklists Adjust service

or routines intervals

Establish standard Verify

times for services service
techniques

Determine service Modify

intervals
checklists

Determine manpower Balance

required by craft manpower needs
October 10, 2021 Slide No 6
 Maintenance ?
Maintenance
Management
 Scheduled Maintenance
 Preventive Maintenance
 Predictive Maintenance
 Emergency Repairs
 Unscheduled Repairs
 Routine Maintenance
 Deferred Maintenance
 Pro - Active Maintenance

October 10, 2021 Slide No 7

 What Does P.M. Mean?
Maintenance
Management

Predictive
Proactive
Productive

Preventive

Pathetic
Phantom
Panic
Passive Availability
Cost/Hour

October 10, 2021 Slide No 8

 Studies Show The Differences Between Proactive &
Maintenance
Reactive Management
Management

 Downtime -- 8 To 1 (Unscheduled Vs. Scheduled)

 Mechanical Availability

 Cost -- 3 To 1 (After Failure Vs. Before Failure)

 Maintenance & Repair

 MTBF (Reliability) -- >80 Hours Vs. <24 Hours

 Number of Repair Incidents

 Planned (Efficient) Repairs -- >80 % Vs. <60%

October 10, 2021 Slide No 9

 Key Questions
Maintenance
Management
 What Are You Doing Now ?
 Why Do You Do What You're Doing Now ?
 What Should You Stop Doing ?
 What Should We Continue Doing ?
 What Should We Start Doing ?

October 10, 2021 Slide No 10

 Can You Answer These Questions ?
Maintenance
Management
 Do You Know Your Repair Costs ?
 Are They Reasonable ?
 What Are the Top Five Repair Costs Items ?
 How Much Downtime Do You Have ?
 What Are Top Five Causes of Unscheduled Downtime ?
 How Much Downtime is PM, R&I, Scheduled ?
 What is Your Major/Minor Component Life ?
 Is it Reasonable ?

October 10, 2021 Slide No 11

 Maintenance System
Maintenance
Management
 Does Your Management System Give You the Information you
Need To Make Informed Decisions

 Machine History/Records
 Machine Hours (Usage)
 Types of Repair
 Types of Downtime
 Cause of Downtime
 Costs, Labor Hours, etc.

October 10, 2021 Slide No 12

 Data Vs Information
Maintenance
Management
 Data  Information
 Serial No.  Production
 Operating Hours  Utilization
 Fuel Usage  Availability
 Top Off Oils added  MTBF & MTBR
 Work Orders Parts/Labor  Load Factor Trend
Problems  Failure Analysis
 Inspections  Manpower Projections
 Component Life  Work Order Performance
 SOS  Budget Performance
 TPMS Date  Failures By System

October 10, 2021 Slide No 13

 Managing Information helps Manage your Machine
Maintenance
Management

With simple commends and user-friendly, MCS gives you control

of a wealth of valuable information about your machines.
With MCS, you can:

 Track all aspects of your maintenance programs

 Be alerted when service, inspections and repairs are needed
 Predict the labor and parts needs for a repair
 See when the work was completed
 Keep details cost records by machine and component

October 10, 2021 Slide No 14

 Lower Operation Costs and Improve Availability
 Maintenance tracking for up to 1,000 machines
Maintenance
Management

 Checklists available from your Cat dealer for most Cat

machine
 On-screen equipment status
 Location tracking of component such as engines and
transmission
 Cost and usage tracking of consumables such as diesel fuel and
make-up oil
 Data import from Preventive Maintenance Planner and Trend
Analysis Module into MCS
 On-line help
 Year 2000 compliant
 Fully translatable

October 10, 2021 Slide No 15

 The Easy Way to Manage your Maintenance

Maintenance
Management
Improve maintenance scheduling
 Keep better records
 Control costs
 Reduce downtime
 Increase equipment resale values

October 10, 2021 Slide No 16

 Scheduling System - What to do/When
Maintenance
Management Heart of the Program - Work in Advance
 Maintenance/Repair  When
 Lube Services  Load factor
 Inspectors  Fuel consumption
 Tune Ups  Idle times
 Component Replacement  Site conditions
 Maintenance
 Parts  Condition Monitoring
 Labor
 Bay Space

October 10, 2021 Slide No 17

 What Preventive Maintenance Planner Offers
Maintenance
Management
 Ability To Customize & Create Checklists
 What preventive maintenance to do
 Checklists for inspectors and lube crew

 When to do it

 Materials and parts needed

 PMP projects labor and materials costs
 Plan downtime and budget

 The ability to transfer information from PMP to Maintenance Control System

software
 An on-line help system

October 10, 2021 Slide No 18

 How Do We Make it Work?
Maintenance
Management
 Maintenance Management System on Site

 Designated Involvement by Position

 Communication

 Teamwork

 Training

October 10, 2021 Slide No 19

 Objectives of Equipment Management
Maintenance
Management

Greater
Profits

Increase Improve
Production Availability

Reduce Reduce Maximize

Repair Costs Fuel Costs Component Life

Maintenance Program

October 10, 2021 Slide No 20

 A Successful PM Program
Maintenance
Management
 Success of the PM program can also be measured in tangible
ways, including:-
 More work is being planned > 75%
 Components are lasting longer
 Downtime is decreasing due to more planned work
 The interval between repetitions of repairs is increasing
 Emergency repairs are less frequent
 Overtime is being reduced as emergencies decrease
 Labor is being better controlled due to more planned work
 Overall costs are being reduced because jobs use less labor

October 10, 2021 Slide No 21

 Preventative & Predictive Maintenance
Maintenance
Management
 Objectives:-
 Avoiding premature equipment failures and ….
 Extending the life of equipment

 PM services are:-
 Routine since the same checklist or procedure is used with each
repetition
 Repetitive because the service is repeated at regular intervals

 They are classified as:-

 Static – carried out only when equipment is shut down or…Dynamic –
able to be carried out while equipment is running

October 10, 2021 Slide No 22

 More Time To Plan
Maintenance
Management  PM services are carried out at:-
 Fixed intervals – Two weeks, six weeks, etc.
 Variable intervals – 250 hours, 10,000 tons, etc.

 Preventive maintenance should have a ‘Detection Orientation’ to:-

 Find problems before they create a failure or stoppage
 Utilize the time gained to plan and schedule the corrective work

 Thus, the ‘Detection Orientation’ of PM assures that early discovery of

problems will yield:
 Less serious problems
 Fewer failures

October 10, 2021 Slide No 23

 Predictive Maintenance
Maintenance
Management

 A deteriorating piece of
equipment is like a stick of
dynamite with a burning
fuse.

 The sooner the problem is

found, the longer the fuse.

October 10, 2021 Slide No 24

 Maintenance Effectiveness
Maintenance
Management

Maintenance Program
* PM
* Inspection & Monitoring
* Planning & Scheduling
* Repair
MTBF

Older
Age
More Complex
Design
Application More Severe
& Operation
October 10, 2021 Slide No 25
A Successful Preventive Maintenance Program Will
Maintenance
Management

 Maximize equipment availability

 Minimize downtime
 Prolong equipment life
 Increase equipment reliability
 Reduce emergencies
 Increase the opportunity for planning work

October 10, 2021 Slide No 26

Maintenance
Management

October 10, 2021 Slide No 27

 Routine preventive maintenance includes:-
Maintenance
Management

 Inspection
 Lubrication
 Cleaning
 Adjusting
 Replacement of minor components (belts, filters, etc)
 Testing and calibration

October 10, 2021 Slide No 28

 Predictive Maintenance or Condition Monitoring
Maintenance
Management

 Technical Analysis Inspections

 Visual Predictive Indicators
 SOS Fluid Analysis
 Vibration Analysis
 Shock Pulse
 Resistance testing
 Infrared scanning
 Sonic testing
 Ultrasonic testing
 Prognostic Diagnostics

October 10, 2021 Slide No 29

 Age Influences Machine Downtime & Repair Costs
Maintenance
Management

B) Major problems creating:

* Stoppage
* Failure
* Blockage

A) Minor problems such as: magnify cost and downtime.

* Heat
* Looseness
* Vibration
B
yield a minimum cost of repair
and downtime.
A

Equipment Deterioration

Cost & Downtime

October 10, 2021 Slide No 30
 Team Work
Maintenance
Management
 Meet Regularly As A Group
 More Information
 Better Commitment
 Better Solutions

 Promote Creative Thinking

 Avoid Misunderstanding/Misconceptions

 Assign Responsibility

October 10, 2021 Slide No 31

 Planning Maintenance & Repairs
A
Maintenance
Management Services due: Shutdown No Maintenance
* Inspection Required Supervisor
* Lubrication
* Testing Yes

Planner Schedule Assign

Services

Work to be planned

Unscheduled Jobs
Crew

A List Perform services:

Advise
Deficiencies * Inspect
* Test
Query
* Lubricate
* Adjust
* Clean
Operators * Replace CP

October 10, 2021 Slide No 32

 Trends:
Maintenance
Management
 Yesterday  Today/Tomorrow

 Operation vs Maintenance  Operation & Maintenance

Teamwork
 Scheduled Maintenance
 Scheduled Maintenance &
 Manufacturer Maintenance
Indicators
 User vs Dealer  Customized Maintenance for
 Internal/Local Focus Local Conditions
 Partnership of User & Dealer
 External/Global Focus,
Benchmarks

October 10, 2021 Slide No 33

 Downtime Data
Maintenance
Management
 By Machine
 By System
 Broken Down For Analysis
 Active Work
 Waiting For Parts
 Waiting For Labor
 Waiting For Transport
 Other Delays

October 10, 2021 Slide No 34

 Effective Use Of Data
Maintenance
Management

 Change Data Into Information

 Analyze Information
 Apply The Pareto Principle
 The 80 / 20 Rule

October 10, 2021 Slide No 35

 Lubrication Service Accuracy
Maintenance
Management
 Average PM Interval = 293
Hours
 Target Interval 250 Hours
Anonymous 793B/C SERVICE ACCURACY - 1997
950
900
850
800
750

PM Hour Interval
700
650
600
550
500
450
400
350
300
250
200
150
100
50
1/1 2/1 3/1 4/1 5/1 6/1 7/1 8/1 9/1 10/1 11/1

PM Date

Which is more meaningful and easier to analyze?

October 10, 2021 Slide No 36

 Analysis - Pictures of Data
Maintenance
Management

100

Hyd
50
Engine
0 Drive
Hyd

Engine
0 100

• Graphs help you visualize TRENDS, TIMING, and RANGE.

• Analysis techniques help you make the rights economic

judgments about your maintenance program.

October 10, 2021 Slide No 37

 Making The Most Of Your Computer System
Most studies showed a mismatch between
Maintenance
Management

what were thought to be problems,

and what the data showed were the real issues.

October 10, 2021 Slide No 38

 Problem Management
Maintenance
Management

Situation Review
Identify Needs/Problems

Plan Maintenance, Organized Process

Records Analysis
Inspection & Repairs to Fully Monitor & Quantity Results
Devise Solution Resolve Problems

Schedule
& Control Activity
Take Action

October 10, 2021 Slide No 39

 What Problem Management Does?
Maintenance
Management

 Identifies the Problem

 Determines the Root Cause of the Problem

 Quantifies the Problem

 Prioritizes Problems

 Utilizes Local Resources

October 10, 2021 Slide No 40

 What Problem Management Does?
Maintenance
Management

 Establishes Ownership
 Promotes Communication
 Promotes Objectivity
 Causes a Solution to Occur
 Effects and Verifies
 Avoids Repetitive Failures

October 10, 2021 Slide No 41

 Maintenance Management Benchmarks
Maintenance
Management

Mechanical Availability 92% (New)

88% (Old)
Mean Time To Repair 3 to 6 Hours
Mean Time Between Failures 80 Hours (New)
60 Hours (Old)
Maintenance Ratio 0.2 (New)
0.3 (Old)
Percentage Scheduled Work 80% - 90%

October 10, 2021 Slide No 42

 Maintenance Management Benchmarks
Maintenance
Management

PM Service Accuracy Within 10% Of Target

Record Keeping -- Repairs 100% (Work Orders)
Record Keeping -- Downtime 100% (By System)
Component Replacements Within 10% Of Target
Component Cost / Hour Analyze $ > 120%

October 10, 2021 Slide No 43

 Maintenance “Facts Of Life”
Maintenance
Management

 Maintenance Has To Be Done

 Maintenance Can Make Or Break Your Operation
 Maintenance Will Be Different Tomorrow Than It Is Today
 There Are Many Effective Maintenance Management
Systems In Operation Today

October 10, 2021 Slide No 44

 Making The Most Of Your Computer System
Maintenance
Management

October 10, 2021 Slide No 45

 Computer System Problems
Maintenance
Management
 Output Is Not Useful
 No Reports
 Hard To Extract Reports
 System Hard To Learn -- Complex
 The Guy That Knew The System Left

October 10, 2021 Slide No 46

 Reality Check
Maintenance
Management  Reality vs Theory
 Who's Really in Charge?
 Is There a Plan?
 Does the Plan work?
 Do the Machines Run the Business or Does the Business Run
the Machines?
 Take NOTHING for Granted
 Cross Check Information
 Check for Customization
 Keep An Open Mind

October 10, 2021 Slide No 47

 Problem Management
Maintenance
Management

Meeting Notes & Action Plan Date

_________
Problem Action Plan As a Person Completion
Item # Description Result of Discussion Responsible Date

October 10, 2021 Slide No 48

 Maintenance Management Principle #5
Maintenance
Management

Maintenance In The Future Will Look More Like

“Maintenance Engineering”

Maintenance Engineering…
…Greater Use Of Data & Information
…Improved Cost / Benefit Analysis
…More Risk / Reward Analysis

October 10, 2021 Slide No 49

Maintenance

The First Rule of Holes

Management

When you are in one…..

….stop digging!

October 10, 2021 Slide No 50

 Maintenance Studies
Maintenance
Management

 Evaluation  Recommendations
 Practices  New Practices
 Procedures  Different Procedures
 Systems  Improved Systems
 Methods  Changed Methods

* Current Results * Improvements

October 10, 2021 Slide No 51

 Maintenance Studies
Maintenance
Management

Have Provided A “Model” Of An

Effective Maintenance System
 Started In 1980
 1 To 2 Per Year
 Maintenance Only
 Corporate Mining Group
 Expanded To Include Both Operations & Maintenance
 Currently At 10 - 15 Per Year

The Basis For The Principles That Follow

October 10, 2021 Slide No 52

 PM Service
Maintenance
Management
 Transport
 Wash
 Lubrication
 Inspection
 Testing
 Repair (Backlog)
 Weld
 Paint

October 10, 2021 Slide No 53

 Proactive Basic Maintenance
Maintenance
Four Essential Elements
Management

 Lubrication (PM) Service

 Condition Monitoring
 Backlog / Follow-up
 Before Failure Repairs

October 10, 2021 Slide No 54

 Condition Monitoring
Maintenance
Management

 Operator Reports
 Daily Inspection
 Complete Inspection (During PM)
 VIMS Data
 SOS - Oil Sampling
 Diagnostic Tests

Why Important?
You can’t be proactive on things you don’t know
about.

October 10, 2021 Slide No 55

 Backlog / Follow-up
Maintenance
Management

 List Of “Problems” (Open Workorders)

 Priorities Established
 Repair Time Estimated
 Labor / Manpower Scheduled
 Workshop / Space Consideration
 Machine Available

Why Important?
1. Planning and control.
2. Communication / Production.

October 10, 2021 Slide No 56

 Maintenance Schedule
Maintenance
DAILY
Management

 Check Fluid levels

 Engine Crankcase
 Cooling System
 Air starter lubricator
 Drain air tanks
 Leaks & loose connections
 Filter gauges
 Air cleaner
 Oil filter differential
 Fuel filter differential

October 10, 2021 Slide No 57

 Maintenance Schedule
250 hour of 41,000L (10,800 gal) of Fuel
Maintenance
Management
 Obtain
 S.O.S. Analysis
 Replace
 Engine Oil & Filters
 Inspect/Clean/Check/Adjust
 Batteries - electrolyte level
 Radiator Fins, Belts & Hoses
 Fuel Tank - Drain Water
 Fan Drive - Lubricate with MPGM
 Injector Timing, Valve Lash and Rotators - (at first oil change only)
 Cooling System - Add supplemental coolant additive (conditioner)

October 10, 2021 Slide No 58

 Maintenance Schedule
1000 hour of 164,000L (43,200 gal) of Fuel
Maintenance
Management

 Inspect/Check
 Engine Protective Devices
 Governor Air Actuator - Lubricate with MPGM
 Replace
 Fuel Filters
 Woodward UG8 Governor Oil (if equipped)
 Clean
 Crankcase Breather
 Primary Fuel Filter

October 10, 2021 Slide No 59

 Maintenance Schedule
2000 hour of 328,000L (86,400 gal) of Fuel
Maintenance
Management

 Inspect/Check
 Turbochargers
 Engine Mounts
 Damper
 Valve Rotators
 Check/Adjust
 Valve Lash

October 10, 2021 Slide No 60

 Maintenance Schedule
3000 hours or 2 years or 491,000L (129,600 gal) of Fuel
Maintenance
Management

 Clean/Flush
 Cooling System

October 10, 2021 Slide No 61

 Maintenance Schedule
4000 hours or 654,000L (172,800 gal) of Fuel
Maintenance
Management

 Inspect & Rebuild or Exchange

 Air Compressor
 Electric Starter

October 10, 2021 Slide No 62

 Maintenance Schedule
6000 hours or 982,000L (259,200 gal) of Fuel
Maintenance
Management

 Replace
 Thermostats
 Inspect and Rebuild or Exchange
 Alternator
 Water Pump
 Air Starter
 Turbochargers

October 10, 2021 Slide No 63

 Maintenance Schedule
Top End Overhaul
Maintenance
Management

 Low Speed Engines (1000 - 1200 rpm)

 11,000 hours
 976,000 L
 258,000 gal
 Medium Speed Engines (1500 rpm)
 9,000 hours
 976,000 L
 258,000 gal
 High Speed Engines (1800 rpm)
 7,500 hours
 976,000 L
 258,000 gal

October 10, 2021 Slide No 64

 Maintenance Schedule
Top End Overhaul (contd)
Maintenance
Management

 Inspect cylinder heads

 Test fuel injectors

October 10, 2021 Slide No 65

 Maintenance Schedule
Overhaul
Maintenance
Management
 Low Speed Engines (1000 - 1200 rpm)
 22,000 hours
 2,920,000 L
 770,000 gal
 Medium Speed Engines (1500 rpm)
 18,000 hours
 2,920,000 L
 770,000 gal
 High Speed Engines (1800 rpm)
 15,000 hours
 2,920,000 L
 770,000 gal

October 10, 2021 Slide No 66

 Maintenance Schedule
Maintenance
Overhaul (contd)
Management
 Inspect, rebuild or exchange
 Cylinder heads, connecting rods, cylinder liners, pistons, turbocharger, cam
followers, fuel transfer pump, prelube pump, injectors, governor, wrist pins
& oil pumps
 Replace
 Piston rings, main bearings, rod bearings, valve rotators, & crankshaft seals
 Inspect
 Crankshaft, camshaft, cam bearings, damper, fuel system linkage, gear train
& bushings, spacer plates, & driven unit alignment
 Clean & Test
 Oil cooler, aftercooler core,
 Obtain a cooling system analysis

October 10, 2021 Slide No 67

 Maintenance Schedule
Maintenance
Management

 Publications
 Maintenance Management Schedule SEBU6103
 Prime & continuous
 Maintenance Management Schedule SEBU6042
 Standby
 Operation & Maintenance Manual SEBU6701
 Prime & standby
 Inspection & Maintenance Program for Standby Generator Sets
SELU6123

October 10, 2021 Slide No 68

 Machin
Maintenance
e PRODUCTION
Management Workin Production
g Availability
Daily Operator Production Daily Log Report
Inspection Operating Hrs

MAINTENANCE Weekly
Maint. Backlog | Scheduling
Daily | Board Mtng
Inspection SCHEDULING
Inspection Checklist Prod/Maint.
SYSTEM
Work Order PM
Shut- Inspection PARTS
Results down Repair
Machine Availability
Work Order Delivery
Analyz
Problem ID & e
Resolution Data Do REPAIR
Scheduled
Update Inspection Management
Checklist Reports FAIL Quality PASS
Control
UPDATE MACHINE
PROBLEM MANAGEMENT
HISTORY FILE

October 10, 2021 Slide No 69