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Best Practice Maintenance Strategy

What is Best Practice Maintenance Strategy?

Maintenance strategy it’s a decision process that will ensure most effective maintenance approach to ensure your assets are able to perform according to their function, when required with the lower risk and cost.

Therefore, the team will decide based on risk assessment, available information and objectives established by the organization what activities might increase reliability, productivity and overall equipment effectiveness (OEE) and reduce failure.

Unfortunately, some organizations wait until a component fails before they take action to repair or replace it. All assets require periodic maintenance to continue running efficiently. Finding the appropriate balance of maintenance approaches is key to minimizing asset downtime and repair costs while maintaining a safe environment for workers.

    There are three basic types of maintenance strategies: 

    • Preventive Maintenance - Preventive maintenance is maintenance that takes place before something breaks down. It is a time-based or meter count-based approach that is carried out at predetermined intervals to reduce failure risk or performance degradation of assets. The aim of preventive maintenance is to minimize unplanned downtime and reduce repair costs. Preventive maintenance cannot always prevent asset failure, however. 
      Regularly performed standard repair, replacement, inspection, cleaning and lubrication. 
       
    • Reactive Maintenance - Reactive maintenance, also known as the run-to-failure or operate-to-failure strategy, is when you take action after an asset fails. Since you only spend money when something breaks, the reactive maintenance approach might seem cheaper but it costs you more in the long run if not part of a maintenance strategy. 
      When this type of maintenance was not embedded on the strategy shortens the life of assets and may cause them to break down more frequently, spending more on spare parts. When you are in reactive maintenance mode, most of your daily maintenance activities are driven by unforeseen problems. 
       
    • Predictive Maintenance - Predictive maintenance is a condition-based approach to maintenance. Rather than servicing assets on a fixed schedule, you evaluate the condition of components to determine whether they need to be serviced. It should be combined with preventive maintenance for the best results. Examples of predictive maintenance include oil analysis, thermal analysis, and vibration analysis. 

     

    Besides these 3, there are other approaches that allow the know-how incorporate the related with technical failures and the changes required to improve the reliability and maintainability on the asset, such as: 

    • Proactive Maintenance - Proactive Maintenance is the integration of RCA analysis, measurement results of the data derived from Predictive and Preventive maintenance. 
       
    • Design out Maintenance  - Design out Maintenance are the asset redesign/enhance performed to improve asset reliability and maintainability to maintain the asset As Good as New.  

     

    What is Reliability-centered maintenance and FMECA?  

    Reliability centered maintenance (RCM) is a reliability tool that is used to ensure the inherent designed reliability of a process or piece of equipment while FMECA mostly is used to define the maintenance strategy for a specific piece of equipment, product line, or facility. Both are developed through the understanding and discovery of equipment functions, functional failures, failure modes and failure effects. 

    Reliability-centered maintenance (RCM) is used to optimize the maintenance program of a company or facility. The final result of an RCM program is the identification and implementation of the most adequate maintenance strategy on each of the assets of the organization. 

    Failure mode, effects and criticality analysis (FMECA) is an extension of failure mode and effects analysis (FMEA).  

    FMECA includes the RPN and a degree of quantitative input taken from a source of known failure rate (such as MTBF), information about pre-failure warning, if the failure is hidden or evident and the failure pattern to support on the maintenance strategy identification. 

     

    Preventive Maintenance 

    Preventive maintenance is maintenance that takes place before something breaks down. It is a time-based or meter count-based approach that is carried out at predetermined intervals to reduce failure risk or performance degradation of assets. The aim of preventive maintenance is to minimize unplanned downtime and reduce repair costs. Preventive maintenance cannot always prevent asset failure, however. 

    Regularly performed standard repair, replacement, inspection, cleaning and lubrication. 

     

    Reactive Maintenance 

    Reactive maintenance, also known as the run-to-failure or operate-to-failure strategy, is when you take action after an asset fails. Since you only spend money when something breaks, the reactive maintenance approach might seem cheaper but it costs you more in the long run if not part of a maintenance strategy. 

    When this type of maintenance was not embedded on the strategy shortens the life of assets and may cause them to break down more frequently, spending more on spare parts. When you are in reactive maintenance mode, most of your daily maintenance activities are driven by unforeseen problems. 

     

    Predictive Maintenance 

    Predictive maintenance is a condition-based approach to maintenance. Rather than servicing assets on a fixed schedule, you evaluate the condition of components to determine whether they need to be serviced. It should be combined with preventive maintenance for the best results. Examples of predictive maintenance include oil analysis, thermal analysis, and vibration analysis. 

     

    Proactive Maintenance 

    Proactive Maintenance is the integration of RCA analysis, measurement results of the data derived from Predictive and Preventive maintenance. 

     

    Design out Maintenance  

    Design out Maintenance are the asset redesign/enhance performed to improve asset reliability and maintainability to maintain the asset As Good as New.  

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    Reliability Maintenance Management

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