Effective Maintenance Program Development/Optimization

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Downloaded from Reliabilityweb.com on the web at http://www.reliabilityweb.comrequirements are applicable and simple service activities are adequate and costefficient. For high and medium risk systems/equipment, verification of all SMTelements is required.4. When an applicable SMT is not available, a more detailed analysis is required forhigh and medium risk systems/equipment. For high risk items, a complete RCM2analysis is recommended, while for medium risk items, RCM2 (FMEA) is sufficientto develop/optimize the maintenance program. The outcome of RCM2 or RCM2FMEA is a set of proposed tasks, their frequencies, and the crafts and skill levels ofindividuals performing the work, or recommended actions in case suitable routinetasks cannot be found.5. For low risk items not governed by any company, standard or governmentalrequirements a run-to-failure strategy is adapted. When requirements exist, routinetasks are developed and incorporated into work packages.6. From the output of RCM2 or RCM2 (FMEA), detailed routine task descriptions aredeveloped and then incorporated into work packages.7. SMTs are developed to reduce tasks development time, efforts, and to ensureconsistency when dealing with equipment from the same equipment group.Developed SMTs are kept in a library for future reference. Routine updates are madeto SMTs to reflect current condition of equipment, gained maintenance and operatingexperience, and any new changes/modification to systems and equipment.8. The final step in the analysis is to upload the developed work packages into PlantReliability Information Management Systems (PRIMS). PRIMS include maintenancesystems such as MAXIMO, SAP Plant <strong>Maintenance</strong>, Document ManagementSystems, Inspection Systems, etc.9. Monitoring developed/optimized maintenance programs is essential to ensure theireffectiveness in meeting the objective set by the organization. An established methodfor recording failure modes, failure effects, and failure causes as well as thecorrective actions taken to eliminate/reduce the failure effects is critical to thesuccessful implementation of any maintenance program.6.2 Standard <strong>Maintenance</strong> Task (SMT)An SMT is a set of maintenance activities, which demonstrate a technically feasible andcost-effective maintenance strategy for a defined equipment group. An equipment groupis a set of equipment of the same class that functions in an identical operating context. Anequipment group has similar design, failure modes and frequencies.Establishing a library of SMTs ensures consistent documentation of maintenancestrategies, reduces the efforts for developing maintenance programs for new systems,Page 8
Downloaded from Reliabilityweb.com on the web at http://www.reliabilityweb.comensures the application of uniform, consistent and cost-effective maintenance activities,and facilitates analysis of equipment groups.It is recommended to include the following information when documenting a standardmaintenance task:1. Applicable company requirements.2. Applicable governing standards.3. Governmental requirements/regulations.4. Completed RCM2 analysis.5. Description of equipment boundary and proper reference to drawings/isometrics.6. Description of operating context (operational and environmental.)7. Assumptions/requirements for/from risk assessment.8. Dominating failure modes with approximate probability.9. The selected maintenance activities to reduce the probability of identified failuremechanisms to cause failure along with the proper intervals (time-based orperformance/condition-based).10. All equipment monitored parameters (RCM2) with their sensitivity to faults/failures.11. Established performance indicators.12. Experience from using a known maintenance strategy along with periodic monitoringof established performance indicators.13. For non evident failure modes, the tests/inspections required to determine equipmentexpected availability.14. Required experience and competency of maintenance personnel.15. Estimated person-hours for maintenance activities.16. Estimated repair time.17. Essential spare parts, tools, equipment, and lead times.The extent of documentation depends on the complexity and the risk assigned to theassets under review. For low risk assets, it is only required to document items one to threeabove and an assessment if simple service activities are adequate and cost effective. Forhigh and medium risk assets, it is recommended that the SMT documents all of the listeditems.6.3 Condition MonitoringThe MTD/O review will determine that the best maintenance strategy is to perform “oncondition maintenance.”Equipment condition is determined by monitoring operational and non-operationalparameters sensitive to failure modes. Since not all parameters are effective in detectingfailure modes, a formal analysis is needed to select the right corroborative set ofparameters. The analysis must identify the failure sensitive parameters and theirmonitoring practicality.Page 9
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Effective Maintenance Program Development/Optimization

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