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Module 1 Maintenance Techniques

Module 1 Machinery Maintenance - Universidad Europea de Madrid
by

Jorge Asiain

on 5 November 2016

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Transcript of Module 1 Maintenance Techniques

Module 1 - Maintenance Techniques
Machinery Maintenance
The technological capacity of companies with respect to maintenance is a key factor for industrial development.
What is maintenance?
It is the action of performing tasks at periodicities to ensure the items functions are available until the next scheduled maintenance period.
MIL-STD-3034
Why is it so important?
Reduce maintenance costs.
Reduce production unit costs.
Increase process stability.
Extend equipment life.
Reduce maintenance spare parts inventory.
Reduce overtime.
Improve HSSE.
Support Continuous Improvement.
Improve sense of employee ownership.
The Time Machine
Corrective
Preventive
Predictive
TPM
RCM
The failures are evident.
No risk for HSSE.
No adverse effect to productivity or quality.
No possibility to implant other maintenance technique.
Age-related failures.
Operational, visual or automated check.
Lubrication, filtration or servicing.
Inspection, functional check.
Restoration.
Discard.
Visual inspections (borescope, stroboscope)
Vibrations monitoring.
Thermography, temperature.
Ultrasonic testing.
Lubricant analysis.
Electrical condition monitoring.
Nondestructive testing.
Autonomous maintenance (Jishu hozen).
Zero fails - Planned maintenance.
Poka-yokes.
5S.
SMED.
Total quality.
Systematic process.
Centered in reliability and failure consequences.
Use decision diagrams.
Determine the maintenance requirements of any physical asset in its operating context.
DEBATE
Jorge Asiain, CEng
Ingeniería Industrial y Aeroespacial
Overall Equipment Effectiveness
Waste = 0
Defect = 0
Breakdown = 0
Accident = 0
5S
Random failures.
Pillars of TPM
Ensuring that physical assets continue to do what their users want them to do.
John Moubray
The process of keeping something in good condition.

Oxford Dictionary


The upkeep of property or equipment.

Merriam - Webster Dictionary
Maintenance signifies methods for the determination and evaluation of the current status as well as for the preservation and reestablishment of the nominal status of facilities, machines and components.
DIN 31051
MOUBRAY, J. RCM II 2nd Ed: Butterwood-Heinemann, Oxford. 1997. pag 6.
BERTSCHE, B. Reliability in automotive and mechanical engineering. Springer, Berlin. 2008. pag 338.
MOBLEY, R.K.; HIGGINS, L.R.; WIKOFF, D.J. Maintenance engineering handbook. 7th Ed: McGraw-Hill Professional, New York. 2008. pag 2.9
ALLIED RELIABILITY. PdM Secrets Revealed. 5th Ed: Allied Reliability, Charleston. 2009. pag 5
FERNANDEZ CABANAS, M; GARCIA MELERO, M; ALONSO ORCAJO, G; CANO RODRIGUEZ, J.M.; SOLARES SARIEGO, J. Técnicas para el mantenimiento y diagnóstico de máquinas eléctricas rotativas. Marcombo Boixareu Editores, Barcelona. 1998. pag 4.
DEF STAN 02-45 Requirements for the application of reliability-centred maintenance techniques to HM ships, submarines, royal fleet auxiliaries and other naval auxiliary vessels. Issue 2. Ministry of Defence. 2000.
DEF STAN 02-45 Requirements for the application of reliability-centred maintenance techniques to HM ships, submarines, royal fleet auxiliaries and other naval auxiliary vessels. Issue 2. Ministry of Defence. 2000.
BORRIS S. Total productive maintenance. Proven strategies and techniques to keep equipment running at peak efficiency. Mc-Graw Hill. New York. 2006. pag. 8.
5 Why
JIT
Kanban
RBM
We can consider RBM as an evolution of RCM. But it makes easier to quantify the failures.
It's based in Risk Based Inspection (API RP 580).

Not only does it allow to design and update the maintenance program, but it allows quantify spare parts and their location, re-design equipments and change processes too.
RCM
Based in
FMEA or
COFA
Qualitative
method
RBM
Based in
RBI
uses FTA
Quantitative
method
Comparative
Expected Cost of Corrective Maintenance:

ECC = (Cc + Cr) X Pf
Expected Cost of Failure (with PM/PdM):

ECFi = (Cc + Cr ) X Pf X (1 - Pp)

Expected Cost of PM / PdM Task:

ECI = Ci + Cpm X Pf X Pp + Cpm X (1 - Pf) X Pe

Expected Cost of PM / PdM:

ECP = ECFi + ECI
Cost of the consequence
Cost of
repair
Probability
of the failure
Probability of
failure detection
Cost of
inspection
Cost of
restoration
Probability of
false failure
CLOUD MONITORING (example)
Full transcript