Introduction to the maintenance
optimization
Jørn Vatn
1
Definitions
■ Maintenance
■ The combination of all technical and administrative actions, including
supervision actions, intended to retain an item in, or restore to, a state in
which it can perform a required function
■ Preventive maintenance
■ The maintenance carried out at predetermined intervals or according to
prescribed criteria and intended to reduce the probability of failure or
the degradation of the functioning of an item
■ Corrective maintenance
■ The maintenance carried out after fault recognition and intended to put
an item into a state in which it can perform a required function
■ Maintenance optimization
■ Balancing the cost and benefit of maintenance
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Scope of maintenance optimization
■ Deciding the amount of preventive maintenance (i.e.
choosing maintenance intervals)
■ Deciding whether to do first line maintenance (on the cite),
or depot maintenance
■ Choosing the right number of spare parts in stock
■ Preparedness with respect to corrective maintenance
■ Time of renewal
■ Grouping of maintenance activities
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“Maintenance theory”
• The bath tub curve is
a basis for choosing
maintenance activities
• There are two such curves
• The hazard rate for ”local time”
• The failure intensity for ”global time”
• Combining the two:
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Performance loss
① The hazard rate for local time
is appropriate for components
such as light bulbs in the signalling
system. Methods are RCM and FMEA
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Preventive maintenance and RCM
■ In this course we have main focus on preventive
maintenance (PM)
■ Maintenance optimization is thus more or less the same
as establishing an optimal maintenance program
■ Reliability Centred Maintenance (RCM) is often
considered to be the “best” approach in this context
■ RCM is a systematic consideration of system
functions, the way functions can fail, and a
priority–based consideration of safety and
economics that identifies applicable and effective PM
tasks
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Renewal and Life Cycle Cost
■ As the system deteriorates, traditional preventive maintenance
activities could not bring the system to a satisfactory state
■ Renewal of the entire system, or part of the system is required
■ The cost of renewal is often very large we need formalised
methods to determine when to perform renewal
■ In this course we will present methods for optimum renewal strategies
based on LCC modelling
■ The following dimensions are included in the LCC model:
■ safety costs
■ punctuality costs
■ maintenance & operational costs
■ cost due to increased residual life length
■ project costs
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Effective failure rate
■ This effective failure rate is the failure rate we would
experience if we (preventive) maintain a component at a
given level
■ Notation: λE = λE(τ)
■ λE is the effective failure rate = expected number of failure per unit
time
■ τ is the maintenance interval
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Effective failure rate and optimization
■ There are two challenges
■ First we want to establish the relation λ = λE(τ) depending on the
(component) failure model we are working with
■ Next, we need to specify a cost model to optimise
■ The cost model will generally involve system models as fault tree
analysis, Markov analysis etc. This enables us to find the
optimum maintenance intervals in a two step procedure
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Introductory example
■ Component model
■ Effective failure rate is given by λ = λE(τ) = τ /100
■ τ is the maintenance interval
■ Total cost of a component failure
■ CMCost = 10
■ Corrective maintenance cost including loss of production during
the repair period
■ Cost per preventive maintenance action carried
■ PMCost = 1
■ The total cost per unit time
■ C(τ) = PM Cost / τ + CM Cost λE(τ) = 1 / τ + τ /10
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Solutions
■ Graphical
■ MS Excel Solver
■ Analytical
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