How is Tero-technology related to maintenance management?

Answer 1

WHAT ARE THE DIFFERENT TYPES OF MAINTENANCE SYSTEMS.

Maintenance Management

Management characterises the process of leading and directing all or part of an organization, often a business one, through the deployment and manipulation of resources (human, financial, material, intellectual or intangible).

One can also think of management functionally as the action of measuring a quantity on a regular basis and adjusting an initial plan and the actions taken to reach one's intended goal. This applies even in situations where planning does not take place. Situational management may precede and subsume purposive management.

Maintenance management will therefore characterise the process of leading

and directing the maintenance organization. Before describing this process, let us make sure that we understand what a maintenance organization, with the resources belonging to it, is pursuing.

Maintenance is defined as the combination of all technical, administrative and managerial actions during the life cycle of an item intended to retain it in, or restore it to, a state in which it can perform the required function (function or a combination of functions of an item which are considered necessary to provide a given service). This definition clarifies the objective of maintenance and can help us to understand what part of an organization is, somehow, devoted to maintenance.

We can define maintenance management as follows :

"All the activities of the management that determine the maintenance objectives or priorities (defined as targets assigned and accepted by the management and maintenance department), strategies (defined as a management method in order to achieve maintenance objectives), and responsibilities and implement them by means such as maintenance planning, maintenance control and supervision, and several improving methods including economical aspects in the organization."

the objectives of the MMS

A. Optimize the use of available funds, personnel, and facilities and equipment through effective maintenance management methods.

B. Provide accurate data for maintenance and construction program decisionmaking.

C. Systematically identify maintenance needs and deficiencies and capital improvement needs at all field stations.

D. Determine the unfunded maintenance backlog for the Service.

E. Establish field station, Regional, and national maintenance and construction project priorities.

F. Enable preparation of Service maintenance and construction budget requests using systematic, standardized procedures.

G. Monitor and document corrective actions, project expenditures, and accomplishments.

H. Conduct comprehensive condition assessments of all Service real property and personal property valued at $50,000 or greater.

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Various types of maintenance strategies

1. Reactive Maintenance

Reactive maintenance is basically the "run it till it breaks" maintenance mode. No actions or

efforts are taken to maintain the equipment as the designer originally intended to ensure design life is

reached.

Advantages to reactive maintenance can be viewed as a double-edged sword. If we are dealing

with new equipment, we can expect minimal incidents of failure. If our maintenance program is

purely reactive, we will not expend manpower dollars or incur capitol cost until something breaks.

Advantages

• Low cost.

• Less staff.

Disadvantages

• Increased cost due to unplanned downtime of

equipment.

• Increased labor cost, especially if overtime is

needed.

• Cost involved with repair or replacement of

equipment.

• Possible secondary equipment or process damage

from equipment failure.

• Inefficient use of staff resources

2. Preventive Maintenance

Preventive maintenance can be

defined as follows: Actions performed on

a time- or machine-run-based schedule

that detect, preclude, or mitigate degradation

of a component or system with the

aim of sustaining or extending its useful

life through controlling degradation to an

acceptable level.

Advantages

• Cost effective in many capital intensive processes.

• Flexibility allows for the adjustment of maintenance

periodicity.

• Increased component life cycle.

• Energy savings.

• Reduced equipment or process failure.

• Estimated 12% to 18% cost savings over reactive

maintenance program.

Disadvantages

• Catastrophic failures still likely to occur.

• Labor intensive.

• Includes performance of unneeded maintenance.

• Potential for incidental damage to components in

conducting unneeded maintenance.

3. Predictive Maintenance

Predictive maintenance can be defined as follows: Measurements that detect the onset of a degradation

mechanism, thereby allowing causal stressors to be eliminated or controlled prior to any significant

deterioration in the component physical state. Results indicate current and future functional

capability.

Basically, predictive maintenance differs

from preventive maintenance by basing

maintenance need on the actual

condition of the machine rather than on

some preset schedule. You will recall that

preventive maintenance is time-based.

Activities such as changing lubricant are

based on time, like calendar time or

equipment run time. For example, most

people change the oil in their vehicles

every 3,000 to 5,000 miles traveled. This

is effectively basing the oil change needs

on equipment run time. No concern is

given to the actual condition and performance

capability of the oil. It is changed

because it is time. This methodology

would be analogous to a preventive maintenance

task. If, on the other hand, the

operator of the car discounted the vehicle

run time and had the oil analyzed at some

periodicity to determine its actual condition

and lubrication properties, he/she may be able to extend the oil change until the vehicle had

traveled 10,000 miles. This is the fundamental difference between predictive maintenance and preventive

maintenance, whereby predictive maintenance is used to define needed maintenance task

based on quantified material/equipment condition.

The advantages of predictive maintenance are many. A well-orchestrated predictive maintenance

program will all but eliminate catastrophic equipment failures. We will be able to schedule

maintenance activities to minimize or delete overtime cost. We will be able to minimize inventory

and order parts, as required, well ahead of time to support the downstream maintenance needs. We

can optimize the operation of the equipment, saving energy cost and increasing plant reliability. Past

Advantages

• Increased component operational life/availability.

• Allows for preemptive corrective actions.

• Decrease in equipment or process downtime.

• Decrease in costs for parts and labor.

• Better product quality.

• Improved worker and environmental safety.

• Improved worker moral.

• Energy savings.

• Estimated 8% to 12% cost savings over preventive

maintenance program.

Disadvantages

• Increased investment in diagnostic equipment.

• Increased investment in staff training.

• Savings potential not readily seen by management.

4.Reliability Centered Maintenance

RCM: "a process used to determine the maintenance requirements of any physical asset in its operating context."

Basically, RCM methodology deals with some key issues not dealt with by other maintenance programs.

It recognizes that all equipment in a facility is not of equal importance to either the process or

facility safety. It recognizes that equipment design and operation differs and that different equipment

will have a higher probability to undergo

failures from different degradation mechanisms

than others. It also approaches

the structuring of a maintenance program

recognizing that a facility does not have

unlimited financial and personnel resources

and that the use of both need to be prioritized

and optimized. In a nutshell, RCM

is a systematic approach to evaluate a

facility's equipment and resources to best

mate the two and result in a high degree

of facility reliability and cost-effectiveness.

RCM is highly reliant on predictive maintenance

but also recognizes that maintenance

activities on equipment that is

inexpensive and unimportant to facility

reliability may best be left to a reactive

maintenance approach. The following

maintenance program breakdowns of

Advantages

• Can be the most efficient maintenance program.

• Lower costs by eliminating unnecessary maintenance

or overhauls.

• Minimize frequency of overhauls.

• Reduced probability of sudden equipment failures.

• Able to focus maintenance activities on critical

components.

• Increased component reliability.

• Incorporates root cause analysis.

Disadvantages

• Can have significant startup cost, training, equipment,

etc.

• Savings potential not readily seen by management.

How Tero-technology is related to maintenance management, Discuss

The term "technology" to refer to the study of the costs associated with an asset throughout its life cycle - from acquisition to disposal. The goals of this approach are to reduce the different costs incurred at the various stages of the asset's life and to develop methods that will help extend the asset's life span.

Terotechnology uses tools such as

-net present value,

-internal rate of return and

-discounted cash flow in an attempt to minimize the costs associated with the asset in the future.

These costs can include engineering, maintenance, wages payable to operate the equipment, operating costs and even disposal costs.

Also known as "life-cycle costing".

For example, let's say an oil company is attempting to map out the costs of an offshore oil platform. They would use terotechnology to map out the exact costs associated with assembly, transportation, maintenance and dismantling of the platform, and finally a calculation of salvage value.

This study is not an exact science: there are many different variables that need to be estimated and approximated. However, a company that does not use this kind of study may be worse off than one that approaches an asset's life cycle in a more ad hoc manner.

THIS APPROACH HELPS TO OBTAINING MAXIMUM BENEFIT

FROM THE PHYSICAL ASSETS. THIS INVOLVES

-systematic application of engineering,

-financial and management expertise in the assessment of the life cycle

impact of an acquisition [ plant/equipment/machines etc ] on the

revenues and expenses of the acquiring organization.

PRACTICE OF of terotechnology is a continuous CYCLE that begins with the DESIGN and SELECTION of the REQUIRED item, follows through with its INSTALLATION,COMMISSIONING ,OPERATION , and MAINTENANCE until the item's REMOVAL and DISPOSAL and then restarts with its REPLACEMENT .