european maintenance standards (3)

European Maintenance Std.

Benchmarking

Maintenance Models

- RCM

- CCFI

- Integration Model - TPM

Development of Maintenance

Compiled By:Rudolf Schenker Pr.Tech.Eng., Reg.Eng.TechMTECH.- Mech. Engineering

© All Rights Reserved 2003

Methods toOptimization

- Implementation

International Maintenance

Standards


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Maintenance: according to EN 13 306:2001

MaintenanceMaintenance

Preventive Maintenance

CorrectiveMaintenance

Condition BasedMaintenance

PredictiveMaintenance

Scheduled/Planned (cycle), continuous or per Order

Forced/UnplannedDeferred or Immediate

Before a detected fault

After a detected fault


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Maintenance Types

immediate reporting,find, control help

planned Inspection,Reliableand correctexecution

j.i.t. andfactual warnings

Inspection order (Report to Operator or Maintenance/Inspection Center)Support during Inspection execution (Guidance, Photos, Documentantion)

tran

spar

ent

thro

ugho

ut t

he

Org

aniz

atio

n of

all

Mai

nten

ance

Pro

cess

es Diagnose the E-Equipment

(Loose Connection...)

All w

ork

stat

ions

Supp

ort u

sing

all M

ater

ial &

Equ

ipm

ent

(Aud

io, V

ideo

- wi

rele

ss, w

eb) Diagnose the Process

(Limit switch not made...)

Monitoring the E-Equipment (Wear/Life expectancy....)

Monitoring the Mechanics (Bearings, Gearboxes, Blowers, Compressors...)

Corrective Maintenance


Predictive Maintenance


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Maintenance Types and its Results

Time and/or Life Cycle driven (km, work hours, poor Quality)

Tran

spar

ency

thr

ough

out

the

Org

aniz

atio

n of

all

Mai

nten

ance

Pro

cess

esUs

ing

a CM

MS.

Reacted too late, i.e. if a Error occurred

e.g. Breakage, Leakage, BreakdownExtreme high Resulting Costs

Just-in-Time-MaintenanceIndicators, CBM

Optimal Maintenance Timing , planned inline

with the Production !

Corrective Maintenance


Predictive Maintenance

Maintenance too often / thus too expensive

immediate reporting,find, control help

planned Inspection,Reliableand correctexecution

j.i.t. andfactual warnings


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

If effective Maintenance Strategies are to be implemented, then the distribution of Maintenance Techniques should be according to the following guidelines:

33 % of the damage caused; to be countered by CBM. (detective maintenance)25% of the damage caused; to combat with Predictive Maintenance5% of the damage caused; to be avoided with Preventive Maintenance33% of the damage caused due to “run to failure”4% of the damage caused due to Design

detective

predictivepreventive

run to failure

redesign

Experiences: Distribution of the Strategic Measures


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Time Concepts: Equipment Availability vs. Demand

Up StateDown State

Idle State Standby State

Operating State

External Disable State

Non RequiredTime

Non RequiredTime

RequiredTime

RequiredTime


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Time Intervals: according to EN 13 306:2001

Time Between Failure (TBF) FailureFailure

Downtime(DT) Up Time (UT)

CorrectiveMaintenance

Time(CMT)

IdleTime(IT)

StandbyTime(SBT)

External DisableTime (EDT)

PreventiveMaintenance

Time(PMT)

OperatingTime

BetweenFailure(OTBF)

MTTR MTTM

MTBFMTBR

MTTFMFT


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Time Concepts: according to DIN 8743

Effective Working Time

Downtime due to Machine

Downtime due to other

Inspection Time

Feed Time

Ancillary Time

Effective Working Time

Overall Working Time

Operating Time

Machine Operating Time

Effective Working Time Total Working time which the packaging machine is operating without breakdown.

Machine dependant downtime

Total time during which the packaging machine is stopped due to faults caused by the machine itself.

Machine in-dependant downtime

Total time during which the packaging machine is stopped due to faults caused by other reasons that the machine itself.

Inspection Time Time required for inspection and measurements.

Ancillary Time Total time where the machine is at standstill due to set-up, format change-over, servicing and cleaning, starting and stopping

Operating Input Number of Blisters or Package output during operating time.

Effective Output Number of Blisters or Package output during overall working time.

Efficiency Ratio Ratio of effective output to set output (actual output/set output)


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Relationships: according to VDI 2246

Production Equipment

Profitability, Environmental, Health & Safety

Reliability Availability

MaintainabilityImprove

Maintainability and/or

Reliability to improve

Availability.

Redundant Reliability

improvements, e.g. complex

Automation/Controls could

complicate the Maintainability.

Maintenance Effort

(Maintainability) will be

high if Reliability is

low.


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Definitions: as per EN 13 306

Reliability: Ability of an item to perform a required function

under given conditions for a given time interval. (rs note: reliability is high (1) when the probability of failure is low))

Maintainability: Ability of an item under given conditions of use, to

be retained in, or restored to, a state in which it can perform a required function, when maintenance is performed under given conditions and using stated procedures and resources. (rs: maintainability is high (1) when maintenance/effort is high (1)

Availability: Ability of an item to be in a state to perform a

required function under given conditions at a given instant of time or during a given time interval, assuming that the required external resources are provided. (rs: Availability is high (1) when equip. is always available for production)


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Wear Definitions: according to DIN 50 320

DIN 31 051: Wear Allowance…considering maintenance, wear is allowed to a state where the functional performance, based on defined operational conditions, is not affected.


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Summary: International Maintenance Standards

DIN 31 051 Maintenance Definitions DIN 13 306 Maintenance Terms and Explanations

DIN 8743 Time Concepts SAE - JA1011 Evaluation Criteria for RCM Processes .

SAE - JA1012 A Guide to the Reliability-Centered Maintenance (RCM) Standard

VDI 2886 Benchmarking Design

VDI 2264 Relationships of Maintainability, Availability, Reliability

DIN 50 320 Maintenance; Wear Definitions EN DIN 32 736 Building Management - Work Areas VDMA 24 196 Commercial Business ManagementDIN ISO 10011 Quality Audit Techniques


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

european maintenance standards (3)

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