Moving From Preventive To Predictive Maintenance To Enhance Efficiency

Preventive, Predictive and
Proactive Maintenance
Plant Maintenance and HSE Middle East 6th Annual Meeting
Moving From Preventive To

Predictive Maintenance To
Enhance Efficiency
Steven Cooke, MChE, FAIC
Senior Quality Management
Engineer
ADGAS
24 November 25 November 2013

Abu Dhabi, United Arab Emirates
Preventive To Predictive Maintenance
Maintenance Activities are the only

controllable factor in risk reduction for
the facility and thus the personnel.
The Cost of Maintenance activities can be

compared to an amortized cost of risk to
demonstrate the cost/ benefit of predictive
maintenance activities with respect to risk
reduction.
Maintenance Management System Evolution

Late 1960s
Maintenan
ce
Strategy
Maintenan
ce
Environme
nt
Skill
Required
Design
Concept
2000s
Breakdown
Preventive
Reliability-Based
Scheduled
Overhaul
Standby capacity
Maximum Capacity Demand
Skilled
Craftsmen
Trained
Technicians,
Time-based
activity
Scheduled
Overhauls
Regardless of
Actual Need,
Large Crews
Dual Standby
Units
High Spare
Inventory
Built In
Obsolescence
Standby
Predictive Technologies
Failure
Operate to
Manageme Failure,
nt
Frequent
Rebuilds
Reliability
Late 1970s
Highly Overdesigned.
Wearout Types
Failures
Over-Designed
Highly Robust
Slow
Root Cause Analysis of failure

Identification Using Condition
Monitoring Tools
Condition Monitoring facilitating a
Predictive/proactive Approach
Design for maximum availability
while operating at capacity.
Higher Precision, Less robust
Reliability Strategy Development
Whats wrong with Preventive

Maintenance?
It is the role of Maintenance to
maximize equipment availability
and reliability. The business
metrics of maintenance are manhours and costs.
The basic functions are corrective
and preventive actions.
Corrective actions may be
planned or reactive. Preventive
actions are always planned.
Whats wrong with Preventive Maintenance?
Reactive maintenance is known

to be more expensive for a plant
overall, and much more
dangerous in hazardous
industries. Unplanned Downtime
is
the resultmaintenance
of system failures.
Preventive
improves the safety factor for
critical equipment, but may be
more expensive than reactive
maintenance from the
maintenance departments
Predictive maintenance offers an

optimization mechanism to allocate
funds and activities according to risk.
This is a more
complex process
requiring better
equipment
condition
information and
computational
abilities.
Review the overall Risk Matrix - it is the

CONSEQUENCES that are most important!
Consequence x Probability = Risk Level

Probability is a direct result of the
Maintenance activities.
Will this function

without THESE
parts?
A critical piece of
equipment requires
reliability and
availability of all
critical components in
order to continue to be
reliable.
Intervene at the best time, not just at

any time!
Maintenance
actions can be
seen as the
difference
between the
protected and
unprotected
incident
probabilities
times the event
consequence
The calculation of
Safety Integrity
Levels (SIL) in
calculating the
reduction in risk due to
actions can be used to
show the cost savings
due impact
to maintenance.
The
of predictive and preventive
maintenance can also be shown against

the realized cost of reactive repair that
includes the opportunity losses of
production interruption as well as the direct
repair costs.
PRIMARY Maintenance
Focus
Bow-Tie Diagram
Planned
Unplanned
Benefits of Predictive Risk-Based

Maintenance
There are useful parallels to training
programs for predictive maintenance: both
require current expenditures to avoid future
errors or faults.
A survey in 2007 by the Aberdeen Group
highlighted some key management factors
for a successful program, including the key
cost factors, which in our context may be
considered the
Cost of Risk Reduction through

maintenance.
Benefits of Predictive Risk-Based Maintenance
Commitment and involvement are required

from plant, production and maintenance
management.
there are no overnight results.
they must contribute to the success of the
program
Plant Manager: Money spent on the
training program (possible overtime, labor
cost, development & instructor costs, material
cost).
Production Manager: Longer down time to

repair machines properly (MTTR).
Maintenance Manager: Trying to juggle
Long-term rewards of the program:

Plant Manager: Decreased downtime,
reduced operating and maintenance costs,
increased employee morale, better safety
performance.
Production Manager: Increased
production uptime and equipment efficiency.
Maintenance Manager: Reduced
breakdowns, more scheduled and less
reactive maintenance, less panic, less stress,
better employee morale, better safety
performance.
Formulate the
Mix
Unplanned Correct
Breakdown
Maintenance (BK)
Planned Corrective Maintenance
(CM)
Preventive Maintenance (PM):
Calendar Time Based
Running Hours Based
Predictive Maintenance (PdM)
Condition Monitoring
Condition Based Maintenance

To Build
Optimal
Sustainabl
e
Production
10. Set KPI
9. - What
are the
failure
modes?
MMS
11. Audit
RCM
2. Review
Equipment
History
1.
Equipment
Criticality
3. Carryout FMEA
FMEA
CYCLE
8. Failures
after
implementi
ng RCM
7. Amend
in CMMS
6. Identify
Tasks &
Recourses
4. Select
Maintenance Type
Based on
equipment
Criticality
Assessment
5. Review
and
Update
Equipment
s Job Plans
Moving to Proactive
Maintenance
Reliability is the responsibility of all

employees, not just maintenance.
Unreliability or failure, and thus
downtime and potential Process
Safety Incidents, are the
consequence of poor processes,
not events.
Therefore, considerable effort must be
devoted to eliminating defects that
cause failure - this is basically
Moving to Proactive Maintenance
Measurements, or KPIs (Key performance

indicators), are used to convey strategic
direction. They allow organizations to select
and evaluate tactics needed for direction and
monitoring of operational performance.
The Avantis Solution to Asset Performance and Reliability - Reliability Centered Maintenance
Enablements of Avantis, 2006 Invensys Systems, Inc
Benchmarks provide a specific comparison of

relevant KPIs against known standards of
performance or complementary processes or
companies considered as good examples of
achievement.
Breakdown of Leaks and Spills by Severity
Gas Sites - 2005
N r o f L e a k s /S p ills p e r N. S P
0.30
0.25
0.20
0.15
0.10
0.05
0.00
DAS
Gas Sites
RAM 0
RAM 1
RAM 2
RAM 3
RAM 4
RAM 5
Gas Average
Gas Trend Group
15
A survey done by the Aberdeen Group in

2007 provided a great deal of support to the
importance of integrated, proactive
maintenance activities in Best-in-Class
manufacturers.
Best-in-Class manufacturers see significant
reduction in year-over-year maintenance
costs (more than twice as likely as Industry
Average and Laggards to see >10%
reduction) while enjoying improved OEE,
OTD, and throughput.
5
Table 1: Preventive Maintenance (PM) Most Commonly Used Strategy

Preventive Maintenance (PM) Most Commonly
Used Strategy
Maintenance Strategies
% of
Employed
Preventive Maintenance
Predictive Maintenance
Reliability Centered Maintenance
Respondents
88%
58%
28%
Best-in-Class Use Proactive Maintenance Strategies

More Frequently
Collaborative Asset Maintenance Strategies, Source: Aberdeen

Group, December 2006
Table 7: Proactive Maintenance Processes Boost Performance Metrics

Proactive Maintenance Processes Boost
Performance Metrics
Maintenance Process
Standardized, enterprise-wide proactive
maintenance processes such as predictive
maintenance, reliability centered
maintenance, total productive maintenance,
and root cause analysis
Average Performance
Asset uptime and availability = 88.8%
Asset productivity (as a % of capacity) = 84.2%
Service & maintenance cost (as a % of revenue) =
17.2%
None or ad hoc and limited use of proactive

maintenance processes. Routine
preventive maintenance the most widely
accepted approach to service assets and
equipment

20.8%
Reactive break/fix work is the primary

approach with little to no preventive or
other proactive maintenance

23.5%

Group, December 2006
Table 7: Proactive Maintenance Processes Boost Performance Metrics

Best-in-Class Reap
Performance (% of respondents in
Significant Benefits
Key Performance Indicator

(Change over past two years)
class reporting improvement)

Best-inLaggard
Average
class
Increases in Asset Reliability
18%
62%
91%
Greater Asset Uptime and Availability
27%
67%
91%
Reduction in Cost of Servicing Assets
3%
21%
39%
Fewer Unexpected Downtimes or Outages
12%
48%
77%
Growth in Return on Invested Capital
7%
21%
66%
Greater Asset Productivity
39%
54%
79%
Higher Yields of Quality Goods Produced
19%
36%
62%
Reduction in Cost of Spare Parts (MRO Inventory)
3%
13%
14%
Longer Usable Asset Life
11%
29%
58%
Fewer Safety Related Incidents
29%
54%
77%
Return on Assets (ROA)
3%
22%
50%
Strategic actions implemented by the Best-inClass tend to be focused on optimizing asset

availability and utilization. Implementing
advanced APM and analytical capabilities
was the top strategic action of the Best-inClass (46%), followed by implementation of
continuous improvement initiatives and
continuous improvement teams. (Note: APM
includes Reliability Centered Maintenance
(RCM), Condition Based Monitoring (CBM),
APM, and optimization capabilities.)
This is followed by improving

effectiveness of maintenance
operations, which is intrinsically tied to
continuous improvement programs.
Specifically, the Best-in-Class are 77% more
likely than the Industry Average and 84%
more likely than Laggards to invest in APM
capabilities such as CBM, RCM,
performance monitoring, and Statistical
Process Control (SPC) tools.
Preventive maintenance covers the range

of periodic tasks (from inspections and
adjustments to component replacement) that
are performed on assets on an elapsed time, or
preferably, a usage basis in order to keep
assets functioning.
Predictive maintenance goes a step

further by using non-destructive testing
methods and condition monitoring to uncover
hidden or pending failures in their primary
mode.
With the fundamental elements in place, the

organization is empowered to truly influence
asset performance and reliability. The
proactive level includes:
Condition monitoring involves tapping

directly into control data sources for statistics
to manage preventive maintenance and enable
instant reaction to failures when they occur, or
preferably, before they occur.
Reliability-centered Maintenance
RCM is defined as A process used to
determine what must be done to ensure that
any physical asset continues to do what its
users want it to do in its present operating
context. 2
1.Failure modes and effects analysis (FMEA) is
a structured analysis based on experience
and what if.
2.Decision algorithm determines the
maintenance action plan and its execution.
Maintenance by
F. Stanley
Nolan and Howard F. Heap,
1978
3.Reliability-centered
Age exploration
- The
continuous
analysis,
2
Demonstrate safety achievements

through Maintenance Performance.
Fewer breakdown or trip events =
Reduced risk due to hazardous
conditions.
Fewer reactive jobs = Less personal

exposure to dangerous activities.
39
Make Safety a key driver for

performance.
Fewer/ smaller
leaks = Less personal
exposure risk
and greatly reduced fire risk.
Planned work = More alert, less stressed

workforce.
40
Conclusi
on
We will not have a safe
plant unless it is a wellmaintained plant
41
The importance of Maintenance is

not about keeping a plant running
well.
It is that keeping it running well
means that it is running safely.
It is improving the employees
workplace safety through
preventive and predictive
maintenance of safety-critical
equipment.
ADGAS Asset Integrity and

Reliability Management
System can be summed up
with a simple sequence:
Do the Right Thing
at the Right
Time
in the Right
Way
Thank you!
Questions?
Email: scooke@adgas.com
WINNER of
the
Steven J. Cooke, MChE, CQE, CQA

Senior Quality Management Engineer
GOLD AWARD 2012

Moving From Preventive To Predictive Maintenance To Enhance Efficiency

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Preventive, Predictive and

Moving From Preventive To

24 November 25 November 2013

Preventive To Predictive Maintenance

Maintenance Activities are the only

The Cost of Maintenance activities can be

Preventive To Predictive Maintenance

Maintenance Management System Evolution

Maximum Capacity Demand

Root Cause Analysis of failure

Preventive To Predictive Maintenance

Reliability Strategy Development

Preventive To Predictive Maintenance

Whats wrong with Preventive

Preventive To Predictive Maintenance

Whats wrong with Preventive Maintenance?

Reactive maintenance is known

Preventive To Predictive Maintenance

Whats wrong with Preventive Maintenance?

Preventive To Predictive Maintenance

Whats wrong with Preventive Maintenance?

Predictive maintenance offers an

Preventive To Predictive Maintenance

Whats wrong with Preventive Maintenance?

Preventive To Predictive Maintenance

Review the overall Risk Matrix - it is the

Consequence x Probability = Risk Level

Preventive To Predictive Maintenance

Will this function

Preventive To Predictive Maintenance

Preventive To Predictive Maintenance

Intervene at the best time, not just at

Preventive To Predictive Maintenance

Preventive To Predictive Maintenance

maintenance can also be shown against

Preventive To Predictive Maintenance

Preventive To Predictive Maintenance

Preventive To Predictive Maintenance

Preventive To Predictive Maintenance

Benefits of Predictive Risk-Based

Cost of Risk Reduction through

Preventive To Predictive Maintenance

Benefits of Predictive Risk-Based Maintenance

Commitment and involvement are required

Production Manager: Longer down time to

Preventive To Predictive Maintenance

Benefits of Predictive Risk-Based Maintenance

Long-term rewards of the program:

Preventive To Predictive Maintenance

Benefits of Predictive Risk-Based Maintenance

Preventive To Predictive Maintenance

10. Set KPI

Preventive To Predictive Maintenance

Reliability is the responsibility of all

Preventive To Predictive Maintenance

Moving to Proactive Maintenance

Measurements, or KPIs (Key performance

Preventive To Predictive Maintenance

Moving to Proactive Maintenance

Benchmarks provide a specific comparison of

Gas Trend Group

Preventive To Predictive Maintenance

Moving to Proactive Maintenance