the development of maintenance (2)

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

The Development of

Maintenance during

Industrialization.


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

The Development of Maintenance Organizations

ShareholdersSales Development

ShareholdersSales Development

Cost Estimation Re-build Repair

Re-build & Repair

ShareholdersSalesDevelopment

Cost Estimation Production

Workshop

1880

1930

1960


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Director

Technical &Development

Financial &Accounting

Production

1980

Sales

Line 1Drawing Office

Line 2

Line 3

Line 4

Analysis

Electrical

Mechanical

Tool-Grinding

Maintenance

Spare Parts Stores

Electronic, Measurements

The Development of Maintenance Organizations


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Director

Technical & DevelopmentFinance &Accounting

Production

2000

Sales

Line 1CentralMaintenance

Drawing Office

Line 2

Line 3

Line 4Analysis, Instrumentation

Specialists

Tool & Cutter GrindingOperation

& Maintenance Spares/Parts Stores

Positioning Maintenance 2005: Asset-,

Facilities-, Resource-EHS-Management,

Consultancies


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Maintenance Management Asset Management

Source; Dave Army, CMRP is the Vice President of Results Delivery for SAMI. http://www.manufacturing.net -

Plant Engineering: Preventive Maintenance 1/27/2003 7:13:00 AM

http://www.manufacturing.net/


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Maintenance Management Facility ManagementSource; Lewandowski & Huber: FH-AugsburgEN DIN 32 736:Building Management - Work AreasVDMA 24 196:Commercial Building Management

Security, Alarms, Access Control Building

Structures

Gas, Water, Air Cond.,Heating,Waste

Disposal

Electrical Supply

& Lighting

Telecomm.,Digital

Processing Units

Transport Systems

Mobile Units,Compressors,

Cranes

Outer Buildings, & Traffic

Facility Management


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Maintenance Consultant Types & Roles:

Type

s of

Con

sulta

ntR

oles

CONSULTANT

CLIENT

DIRECTIVE NON DIRECTIVECONSULTANT ROLES

AD

VOC

ATO

R

TEC

HN

ICA

LEX

PER

T

TRA

INER

EDU

CA

TOR

MO

DER

ATO

R

ALT

ERN

ATI

VEID

ENTI

FIER

REF

LEC

TIVE

OB

SER

VER

FAC

TFI

ND

ER

PRO

CES

S SP

ECIA

LIST

Deg

ree

ofIn

volv

emen

t


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Maintaining Quality levels

during Production Maintenance Safety for Man & Environment

Minimum Maintenance Effort

Necessary TransparencyGuaranteed

Minimum Unplanned Breakdowns in Main areas.

Maintenance Requirements


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

What is Maintenance?

According to DIN 31051:

the conservation or the repair of all types of technical objects/equipment to their planned state, i.e. replacement, refurbishment, upgrade or repair.

Conservation? By cleaning, lubrication, small repair, wear-part exchange.

Planned State? Obtaining the Functional Ability again by damage- control, -identification, -verification, repair and replace.

monitoring and evaluating the current state of technical objects/equipment, i.e. inspection, CBM, Thermography,

How? By checking, documenting and evaluating the wear, deformation, aging and corrosion, and predicting with time.Source: Die Gesellschaft für Instandhaltung


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

ERP-Systems

External Contractors

Benchmarking

Automation Systems

Production Planning

The Maintenance Landscape and Integration.

Condition Monitoring

MaintenanceMaintenance

Spare Part Systems


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Maintenance vs. Other Industries

The Maintenance sector in Germany is leading: Analysis of the “Gesellschaft für Instandhaltung (GFIN)”Maintenance 265 bil. DM TurnoverAutomotive 264 bil. DM TurnoverMining 256 bil. DM TurnoverElectro-technique 237 bil. DM Turnover

Source: Maschinenmarkt, Würzburg 103 (1997) 39


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

The Need to Optimize Maintenance.

„Sloppy Maintenance cost the Industry 1,5 Billion Euro“ 1

Research showed; Maintenance Cost for the German Industry increased with 3% to ± 150 bil. Euro per Year (only direct Cost)

Costs caused by Machine Downtime, Loss of Image, Quality and Delivery Capability are estimated by the German Council for Maintenance2 4 to 5 higher as estimated direct Costs.

1 Magazine Extract: Produktion, Heft 50/51 2001

2 Gesellschaft für Instandhaltung (GFIN)


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Why is Maintenance so important?

The X-Factor of Maintenance

60's 70's 80's 90's 00's

Productivity

Maintenance Costs

Because the Availability of the Assets (Machines, Plant and Equipment) are always more important, deserving preference!!!

Due to no and poor maintenance

planning

Time

Prod

ucti

vity

& M

aint

enan

ce C

ost


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Downtime Costs.

0

20

40

60

80

100R

eact

ive

Mai

nten

ance

Plan

ned

Mai

nten

ance

1

Plan

ned

Mai

nten

ance

2

Contingency

Machine Cost

Scrap

Wages

Material

Salaries

NB: Often underestimated and not calculated:

The Costs Resulting from Breakdowns!!!

Eliminate Resulting Costs by Preventing Breakdowns:

%

Breakdown costs due toRe-active Maintenance


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Why is Maintenance gaining Priority?

Competition Customers rule, the deliverability, (Audits, Certification, ...)

The cause of a breakdown will not be accepted anymore.

Late delivery leads to loss of clients!

Regulatory Facts

Traceability

EHS is regulatory and must be traceable.

Guaranteed Performance as a deliverable

New measurements for product liability

Internal Facts

Skills & knowledge to be secured

Maintenance is part of QS

Better planning for employees and resource application

Seamless integration of maintenance and production

Profitable Facts

Downtimes too high

too many unplanned breakdowns

Capital-binding for MRO too high

Personnel costs not transparent

Extending machine & plant lifespan.


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Production Orientated Goals for Maintenance:

Increasing the Availability and Performance of Production- / Plant, Vehicles, Hardware, Software, ... by

Prevention of Breakdown through Planned- and/or Historical/Outcome Guided- and/or Condition Based-

Maintenance Shorter reaction times at Breakdown and

minimizing the Breakdown Period. Early Detection of potential Problems/Weak Areas Increasing the Production Capacity and Quality Service and Inspection, so that Maintenance activities

are integrated with Production planning, and not done during Breakdown.

For Planned Maintenance can be Calculated, an unplanned Breakdown is Expensive!


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Business Management Goals for Maintenance:

Business Advantages:

Reducing the Maintenance Cost through:

Optimizing Services, therefore increasing Services Employee Productivity.

Reducing the Spares & Stock levels Reducing the Spare part varietyCost transparency by allocating the Material/Work time to Equipment and Plant, correctly.

Increasing the „Return on Assets“


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

Goals are… The management of Assets, Specifications, Standards,

Quality Management and Information Efficient Planning and Termination

Maintenance Planning; Visibility and Evaluation of

executed Maintenance Replace- and Wear- parts, fast and easy to obtain. Reduction of Spare Part Acquisition. Reduction of „making the same mistakes, again.“ Increasing the Productivity of Maintenance. Reducing the Maintenance Costs.

Background Facts


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

A Client/Server - Solution A Management Tool, used to optimize

Maintenance, Material Management and Acquisition supported:

Technical Objects (Assets) => Machines, Plant and Material

Maintenance OrdersPlanning and TerminationPreventive MaintenanceStorageAcquisition

Stores MaterialNon Stores MaterialExternal Services

Background Facts


Benchmarking

Maintenance Models

- RCM

- CCFI






- Implementation

the development of maintenance (2)

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