In this guide, we will show you everything you need to know about how to abbreviate maintenance, so keep reading!
Below you can find out 5 different methods to abbreviate maintenance,
- Method 1 – 3 Maintenance Strategies: Which Works Best?
- Method 2 – Abb – Reliability-Centered Maintenance
- Method 3 – Abb Ability™ Predictive Maintenance For Grinding
- Method 4 – Response Maintenance
- Method 5 – Preventive Maintenance Powered By Servicepro
Method 1 – 3 Maintenance Strategies: Which Works Best?
What are the three maintenance strategies that are commonly used to manage assets and how do they differ first is. Referred to as reactive or corrective maintenance the second is known as preventive maintenance and the third is predictive maintenance. Lets take a look at how they differ with reactive maintenance an organization does nothing until the asset fails and. Then responds with preventive maintenance an organization performs tasks on regular intervals until failure occurs with predictive maintenance the tasks.
Vary depending on the age and changing condition of the asset over time at particular points along the curve certain. Leading indicators of failure can be detected and addressed proactively reactive maintenance an organization may not be able to achieve. The full service life of the asset when an asset failure occurs early some of the potential life of the. Asset is lost with preventive and predictive maintenance the organization is able to potentially achieve the full service life using. The proactive planning methods which vary in their mitigation effects an organization will apply one of the three maintenance strategies.
Depending on its future orientation and attitude to managing failures with reactive maintenance there is no attempt to gain insight. Into the future issues are managed in the here and now with preventive and predictive maintenance an attempt is made. To look into the future the difference however is that preventive maintenance seeks clarity only until the next planned maintenance. Task predictive maintenance however tries to anticipate the eventual failure of the asset and works backwards from that event there. Can be a significant monetary impact of the three maintenance approaches reactive maintenance is cheaper in the short term but.
More expensive in the long term as the organization incurs additional costs from a shorter asset life preventive maintenance incurs. Fixed costs at fixed intervals which may not reflect the change in condition of the asset predictive maintenance incurs more. Upfront costs such as the acquisition of diagnostic equipment and staff training it is however aligned most closely to the. Changing condition of the asset both preventive and predictive maintenance are able to mitigate the failure cost through their proactive. Steps over the life of the asset finally maintenance activities can also be plotted onto a deterioration curve the graded.
Color scheme reveals the changing risk profile of the asset being maintained with reactive maintenance no action is taken before. Asset failure and the organization can be caught off guard preventive maintenance follows a fixed interval approach until the asset. Fails predictive maintenance on the other hand applies variable intervals of maintenance as the asset condition changes at the end. Of the day each asset needs to be aligned to an appropriate maintenance strategy these decisions are based on many. Factors including the criticality of the assets regulatory requirements and the availability of diagnostic technologies to reveal concealed conditions.
Method 2 – Abb – Reliability-Centered Maintenance
Hello my name is dave bureaus im a global product marketing manager for abb process automation service and today were. Going to learn about an important service concept called reliability centered maintenance now why would we want to learn about. Reliability centered maintenance its considered the world-class maintenance approach for process industries and manufacturing and other industries as well so. Were going to cover three main areas in this presentation its just an overview but those three main areas are.
Equipment criticality and analysis failure modes and effects analysis on the equipment and some basics about how to implement reliability. Centered maintenance so lets start with the definition of reliability centered maintenance reliability centered maintenance is a high-level maintenance strategy. Thats meant to optimize all the assets in the facility and it uses a variety of maintenance approaches to put. Together an overall approach thats meaningful for every different system or equipment category and these maintenance strategies are optimized to. Really provide the most overall efficient functioning of the plant so the notion of preventive maintenance is that the more.
Preventive maintenance we do as you can see here in this line is curving up these bars that curve up. Here then the fewer unplanned maintenance activities will be required those are breaking fixed emergency repairs what also happens the. More preventive maintenance that we do the actual planned maintenance hours also come down were just doing things more effectively. And we see cost benefits across the board but what if we do too much preventive maintenance is that possible. It is possible theres a sweet spot where we only want to do the right kind of maintenance at the.
Right time if we touch the equipment too much we can actually induce failures that are costly or we can. Just spend too much time maintaining equipment and the actual cost will beginning to creep up so we want to. Be right here in this sweet spot so what did we have before reliability-centered maintenance well first of all we. Had reactive maintenance something breaks and we go and fix it the idea is to get that equipment back up. As quickly as possible theres no real preventive maintenance with that approach costs arent really considered that carefully its popular.
Because its very easy to deploy something breaks and we go fix it its very in effect its a very. Inefficient use of manpower and capital well weve already discussed preventive maintenance of course thats the next step if we. Can address something that might break on a piece of equipment before it breaks then were step ahead of the. Game but as i also said its possible to do too much preventive maintenance we dont want to do too. Much but still thats a step in the right direction and its usually time directed we do it on a.
Regular basis every six weeks were going to lubricate a piece of machinery then we go to proactive maintenance this. Is the notion of looking at a production line or a piece of equipment even before its put into operation. And make sure that its easy to access to maintain or to look at equipment say is that equipment is. That piece of equipment easy to maintain should we replace that equipment or if youre building a plant or building. A new line you can have that as a criteria of looking at new equipment as this equipment easy to.
Maintain thats proactive maintenance theres also predictive maintenance this is when we use a variety of technologies such as infrared. Or thermography or lubrication analysis different kinds of technology to assess a piece of equipment even while its in operation. That might be able to determine certain things on that piece of equipment that we cant see with our naked. Eye or we cant hear that will alert us hey something needs to be addressed here then finally we get. To reliability centered maintenance and as i mentioned before reliability centered maintenance takes advantages advantage of all of those things.
And only chooses the right approach for the right piece of equipment even reactive maintenance or a strategy might be. To not choose any maintenance approach at all all right strategy might be to just let a piece of equipment. Run the failure if its low-cost and you have a hot spare maybe its just too costly to try to. Touch that on a regular basis let it feel alright so lets talk about the three main steps to effective. Reliability-centered maintenance the first one is to make sure that you preserve equipment functionality by establishing criticality levels of the.
Equipment the second was to is to identify and prioritize failure modes once we understand what the equipment criticality is. Then we can start looking at whats likely to fail on this piece of equipment and put together some plans. To address it and then thirdly implement reliability centered maintenance by choosing the correct approaches so for criticality let me. Just state this clearly the first consideration for criticality should always be safety here we have an example of a. Refinery in asia i wont name the country that exploded in 1992 and the explosion killed a number of people.
And injured many more when the analysis was done on why the explosion occurred it was determined that it was. Really a maintenance failure you see there some of the reasons for why repeated ratcheting reducing diameter of a gasket. Retainer well im not that familiar with this case but repeated ratcheting that could be an example of too much. Preventive maintenance so the right maintenance approaches werent taken here and it led to a disaster so as i said. Safety is always number one when youre putting together criticality analysis environmental is up there in the same level of.
Safety the next consideration is production stoppage if youre not making product youre not making money the third one is. The maintenance expense how costly is it to repair a certain piece of equipment the fourth is the effect on. The systems remember systems is a collection of equipment so what is the effect if something breaks here what kind. Of effect will a ripple effect will have on other pieces of equipment it could be a big effect so. Take that into consideration and fifth redundancy does this production or is this process have some redundant features so that.
If it fails in one area it except in another area thats lacking redundancy then it could be a higher. Level of criticality we put those criticality xin to certain levels so this is an example of criticality level number. One first of all if a failure occurred here then it could result in a loss of life or would. High likelihood of resulting in loss of life or limb or permanent disability high likelihood of an environmental emission high. Likelihood of a very costly impact on production and high likelihood of a costly equipment repair maybe theres no redundancy.
With that system so that would get a criticality level number one we just go down there criticality level number. Two might be a measurable impact on safety and environmental or or a less costly impact production or a less. Costly maintenance you get the idea level three just a potential still something to watch out for but not high. Likelihood and then number four no safety effects no environmental effects no impact on production very minimal minimal maintenance cost. And maybe theres multiple redundancy and in this loved one so you just dont have to worry that much about.
It so those are criticality levels and before we can assign criticality we need to establish the systems systems is. A group of components and equipment category piece of equipment and all the sub components or it could just be. One singular complex piece of equipment heres an example wed have a major system with major sub major assemblies major. Sub assemblies components and we get down to a part level for example a compressed air system wed have compressor. Assemblies compressor units each compressor unit would have a motor or compressor and controls and then you get down to.
A parts level with a motor so we i want to identify all the major components of a system group. Them together if we can just do in a sensible fashion so for instance we would have with that same. Kind of example we would have and our failure modes and effects analysis worksheet wed have the compressed air system. Looking at the subsystem of air compressor assembly and the components would be compressor motor and valve then we want. To identify the failure modes what could go wrong with each of those components so that for a compressor for.
Instance it might seize and that would be a failure for motor might fail to start failure valve fails to. Close failure next we want to look at the failure mechanisms what would cause these things to fail heres just. Some examples could be corrosion or erosion or a part fails or its not calibrated so forth so again in. Our example with a compressor the failure mode is that it seizes and what would cause that might be a. Bearing failure so we just go through all of our systems like that and fill out this sheet and we.
Create a likelihood table of that happening with a level such as this remote very low low high up to. Extreme we also want and effects descriptions so if we think about the levels that we defined earlier when we. Were talking about levels of criticality a level one criticality would be loss of life body part or lost-time accident. And so forth so we want to identify those specifically because we want to apply we want to have an. Apples-to-apples comparison with all the systems in the plant so again back to our example we have with a compressor.
We have the likelihood of it happening as ranked high and we also have the failure effect also ranked i. Would have a major impact on production then we want to put together the actions that we would take if. There were a failure so we put together a list of recommendations if a compressor ceases as a result of. A bearing failure we know that thats high likelihood and also high negative impact on production so the recommended action. Is to maintain lubrication so that was just a very cursory overview of what criticality analysis failure mode and effect.
Analysis is now well talk briefly about how a plant would actually implement reliability-centered maintenance first of all you want. To make sure you have a team a cross-functional team you would have that included mechanical maintenance instrumentation electrical maintenance. Process control operations systems or plant engineering and perhaps a facilitator you want to understand your current maintenance processes after. Youve done that criticality analysis and the failure mode and effect analysis you might have identified areas where your processes. Just wouldnt allow you to really effectively act on the recommendations that you just put together as part of the.
Failure modes and effects analysis you want to put together a plan then to address those areas that might be. Weaknesses in your processes start by setting goals what we really want to do here do we want to increase. Production what are the plants business goals are we starting up a new line and so we want to get. It right the first time do we need to reduce maintenance costs put together your approach how are you going. To track it how are you going to whos going to be responsible for what make sure that people know.
That theyre accountable so theres a name for certain action so it doesnt fall into the cracks finally implement into. An enterprise asset management system also known as a computerized maintenance management system this is software that where work orders. Can be implemented and the preventive maintenance routines can be in there and the planning and scheduling can be done. There and all the things that weve just discussed can all be implemented in there and it expedites effective implementation. Of reliability-centered maintenance now abb has its own computerized maintenance management system for abb equipment and thats called service pro.
But service pro is uniquely designed for abb use for abb equipment and processes and it comes already with a. Hierarchy of systems and subsystems and components that you see here it also comes with the preventive maintenance routines already. Embedded in there so those things that we saw that our result of a failure and effects analysis many of. Those things are already embedded in the service pro for many abb asset classes service pro is also very helpful. For customers and doing their criticality analysis what you see here is an analysis of the service events and the.
Number of hours spent maintaining specific pieces of equipment you see here that analyzer 1200 has had a high number. Of service instances and also a high amount of service hours well that will tell the customer perhaps its a. Critical piece of equipment that we need to put in a different level a higher level of criticality or maybe. Thats a piece of equipment that needs to be addressed or redesigned or even replaced service pro also provides benchmarking. For specific pieces of equipment at other sites around the world that had that same kind of that same piece.
Of equipment since service pro is used by abb engineers and customers at hundreds of sites all over the world. A customer can look at this kind of data and see the piece of equipment my plant needs more repair. Than that same piece of equipment at many other customer sites is there something wrong with the way im maintaining. It does that piece of equipment need to be replaced all of this is an important contribution to a criticality. Analysis and failure modes and effects analysis another tool that abb has that will help customers very much and doing.
A criticality analysis and a failure modes and effects analysis as part of a reliability centered maintenance implementation is advanced. Services powered by service port as many of you know and we deliver advanced services we are gathering lots of. Data and analyzing that data and identifying categorizing and prioritizing things that need to be addressed the same thing that. Happens in a failure modes and effects analysis here is a typical screen that youd see in a fingerprint report. Or on the service port itself that would show the systems or subsystems or components that we are monitoring or.
Gathering data from with the advanced service and with this size bar we see events that might indicate that that. Piece of equipment needs to be looked at more closely or that component needs to be looked at more closely. So again that would be a great contributor to a customer undertaking reliability-centered maintenance program wed love to be able. To provide that that kind of analysis for customers for all of their systems right now we only offer them. For certain important abb asset classes we provide that kind of analysis via advanced services powered by service port for.
The harmony control system system 800 xa lv drives mine hoists and quality control systems for the paper industry so. Thats just a brief overview of reliability centered maintenance thank you for your time you.
Method 3 – Abb Ability™ Predictive Maintenance For Grinding
This year in 2021 we are celebrating abvs 130 years of writing the future of mining across the years we. Developed the knowledge to further understand the importance of our equipment at the different mining processes our grinding mill powertrain. Portfolio for instance a gearless meal drive known as gmd represent a critical technology asset which guarantees a continuous and. Reliable production for our customers ten years ago we initiated a pioneering path in our grinding digitalization journey in which.
We have been developing digital products that allows us to remotely monitor and manage our fleet now we are taking. Another step further and introducing our new avb ability predictive maintenance for grinding solution what is new compared to the. Existing solution we have migrated to a cloud-based platform which allows us to enhance and innovate our platform features giving. More flexibility and reliability to our customers this upgrade means on the one hand improved interfaces and user experience for. Customers so that they can decide which kpis are essential for the daily operation this allows operations to have access.
To information from anywhere in the world through a simple and secure personal connection on the other hand since we. Understand the value of making decisions based on real-time data algorithms and trend analytics have been improved thanks to this. Enhancement we support our customers with a predictive tool that facilitates quick decision making by detecting fluctuations and variation in. Real time during their operations in todays world whether it be checking our health or catching up on the news. We utilize our mobile devices more and more the avb ability predictive maintenance for grinding includes a brand new mobile.
Application that allows real-time notifications of your fleet with a simple overview on your device you know the status of. Your fleet receive alarms when needed and know how your meals are performing at your fingertips at any time and. Any place finally avb ability predictive maintenance for grinding represents the next generation of collaborative products maximizing the availability of. Your assets and supporting you in a safe and reliable way lets continue writing the future of mining together you.
Method 4 – Response Maintenance
Response maintenance this is where your response maintains past the time with which its been trained but kind of continues. To train in shock you did you do these videos classic example of response maintenance why you might ask because. Dr. Brigham and dr.
Clea theres a doctor all sorts of doctors a lot of people taught me these things. It starts dr. Mcsweeney sorry friend and so all these people taught me these wonderful things about behavior analysis and. My responses are maintaining long past being out of there instructive classrooms so so the response maintains past the time. That the intervention is over if you love so how long does the person keep maintaining their ability to communicate.
Functionally do they do that for six months after you taught them to the fc is sometimes some fct or. Do they do it for four minutes because its all maintenance but its about how long does that behavior maintain. Four right so thats what were talking about when we talk about response maintenance how long does it continue is. They can do it did you put them in touch with the natural contingencies if so then the response is. Gonna maintain its that simple geez hard beating around a bush here.
Method 5 – Preventive Maintenance Powered By Servicepro
Hi im tim man and id like to talk to you about preventive maintenance everyone agrees that we should do. Preventive me on our equipment there are a lot of questions surrounding it what preventive maintenance should we be doing. How often should we do it are we doing the right amount who has the skills to do it abb. Has a solution to all these questions in the service pro maintenance management plan service pro is a custom service.
Maintenance platform designed the answer this very question what should we be doing within service pro we review your installed. Base of equipment then we cross-reference that with a master library preventive maintenance from the equipment manufacture this allows us. To develop a customized maintenance plan based on your particular mix of class how often should we do different tasks. Need to be performed at different scheduled intervals service throw is capable of managing tasks at the daily and weekly. Level the monthly and annual and even multi-year preventive maintenance schedules that are difficult to track and monitor service pro.
Helps you do the right thing at the right time are we doing the right amount its difficult to find. The correct mix between preventive maintenance and corrected me if we do too much preventive maintenance were wasting our maintenance. At all but we dont do enough were running the risk of costly and expensive downtown with in service throw. We get the recommendations directly from the manufacturers as to what preventive maintenance we should be doing but then we. Cross-reference that with industry use of statistics derived for more than two and a half million completed work orders within.
Service road to develop a custom maintenance plan particularly for you and who has the skills of you we recognize. That you have lots of skilled engineers who are capable of forming your preventively but sometimes you need experts from. Outside to come and give you an assistant in addition sometimes theres some preventive maintenance that based on your particular. Usage you might decide you just dont want to do so we work with you to build a custom contract. To determine are you doing the maintenance abb doing the maintenance where is no wonder analysis this helps you get.
The right balance for your process right balance for your budget and the right balance for your equipment abb service. Pro platform helps you to right-size your preventive maintenance to get the best out of your equipment.
Conclusion – How To Abbreviate Maintenance
The purpose of this post is to assist people who wish to learn more about the following – asset maintenance optimisation – reviewing and upgrading your pm routines, 5 steps to tailor made maintenance service agreement from abb, 4 tips for improving maintenance productivity, how to select the right maintenance strategy for electric motors, abb abilitytm predictive maintenance services for grinding, 4 types of maintenance organisation, how to offer your clients an excellent website maintenance plan or retainer, do it yourself : landscaping maintenance, basic maintenance on the john deere 1023e (1025r), learn how software maintenance can accelerate factory productivity, cut your commuting costs: basic maintenance, maintenance from abb low voltage circuit breakers, assetinsight – future of operations and maintenance strategies – webinar, bench talk: equipment maintenance, -.
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