1. Welcome to ATF205 Introduction to Modern Maintenance Practices ► Dr David Baglee ► david.baglee@sunderland.ac.uk david.baglee@sunderland.ac.uk ► Phone: 515 2869 ► http://osiris.sunderland.ac.uk/~cs0dba/ AMAP The Industry Centre Wessington Way ► Thursday 1pm-5pm (including project management) ► Lectures and lab. ► Two assignments

2. Maintenance and Asset Management Links ► http://www.skf.com/aptitudexchange/glossar y.html http://www.skf.com/aptitudexchange/glossar y.html ► http://www.reliabilityweb.com http://www.reliabilityweb.com ► http://www.reliabilityweb.com/excerpts/ http://www.reliabilityweb.com/excerpts/ ► http://www.maintenanceresources.com http://www.maintenanceresources.com ► http://www.maintenanceworld.com http://www.maintenanceworld.com ► http://www.plant-maintenance.com http://www.plant-maintenance.com ► http://www.mt-online.com http://www.mt-online.com ► http://www.cmmscity.com/articles/cmms_arti cles.htm http://www.cmmscity.com/articles/cmms_arti cles.htm

3. Introduction to Maintenance Dr David Baglee School of Computing and Technology

4. Maintenance Spending ► Europe €120 Billion Annual Spend Employs 2 million people ► United Kingdom £16 Billion Annual Spend Employs ? No records indicate reactive maintenance spending

5. Trends ► Assets Assets must run longer Impact of asset failure can be very large ► Expertise Downsizing and aging workforce has caused ‘skill gap’ at plant sites Technology is evolving faster than it can be adopted ► Working Practices Asset management is moving from reactive to proactive Abnormal situation management procedures are improving operations effectiveness

6. Recent Events ► Tube Crash - Chancery Lane, London Bolts holding motor failed, train derailed 30 hurt. £ms lost ► Electricity Supply Failure - USA, Italy, UK ► Rail Crash - Hatfield, UK 4 people died: lack of maintenance on lines ► Concorde Crash - CdG Airport, Paris ► BP Refinery Explosion, Texas Vent system not maintained $ms damage loss of life ► Food contamination at Cadburys: Unchecked pipe during maintenance leaked oil, 75’000 bars recalled

7. Example: Car Maintenance ► What must be done to maintain your car? Change the oil every 6,000 miles Check and/or change air filter Check and/or change hoses and belts Clean inside/wash outside Replace brake pads Regular inspection

8. Maintenance Strategies ► Run-to-fail ► Time based ► Condition Based ► Modern Maintenance Reliability Centred Maintenance (RCM) Total Productive Maintenance (TPM) Condition Based Maintenance (CBM)

9. Period between 1900-Present Characteristics of equipmentMaintenance philosophy First generation maintenance (1900-1939) Equipment is simple and easy to repair Basic and routine maintenance Reactive maintenance, “only repair when broke” Second generation maintenance (1945-1979) Equipment is more complex, greater dependence of industry on equipment Maintenance costs are higher in relation to other operating costs Planned preventive maintenance Time based approach Total Productive Maintenance (TPM) ‘Total' employee participation. Team based approach to maintenance, examines “culture and people” not systems Third generation maintenance (1980s- present) Equipment complexity increasing Accelerated use of automation Downtime very expensive Increasing use of Just-In-Time Customers now demanding higher quality goods Tightening legislation on safety Condition monitoring (CM), hazard studies, failure modes and effect analysis Reliability centred maintenance (RCM) examines “machine and systems” Computer aided maintenance management Multi-skilled workforce Emphasis on equipment reliability and availability Maintenance is now proactive and strategic

10. Example: Car Maintenance ► Implications of poor car maintenance? Premature failures Increased running costs Unexpected breakdowns Personal injury or death Government shuts you down

11. Poor planning

12. Barriers to maintenance strategy development ► Limited staff ► Lack of training ► Inadequate diagnostic equipment ► Missing technical documentation ► Budget issues ► Inadequate monitoring of equipment ► Lack of management commitment ► Poor morale

13. Neglected Maintenance ► Operating equipment in manual override ► Incorrectly adjusted equipment ► Inefficient operations ► Inoperative equipment ► Steam, air, water leaks ► Faulty control systems

14. Results of Poor Practices ► Short and Long term effects: Increased energy costs Increased major maintenance work Increased capital costs due to shortened equipment life Continued morale degradation HEALTH & SAFETY INNAPROPRIATE TASKS

15. Correct Strategy? Planned? Cost effective Safe Identify ‘why’ Alternative task?

16. Costs Involved ► Equipment purchase ► Training ► Extra staff ► Costs can be insignificant when compared with cost of not improving maintenance methods ► Industry loses per year are huge due to inadequate maintenance activity

17. Benefits ► Improved equipment efficiency ► Increased product quality ► Identify equipment defects ► Reduced equipment failures ► Increased production ► Improved safety ► Minimize damage to equipment ► Provide guidelines for new equipment purchase ► Effectively prioritize decreasing resources ► Improve staff morale

18. Recent Advances Equipment 1.) PDA 2.) Cost £250 3.) Metal-on-mount ICode RFID Tags: 10p 4.) USB Vibration Sensor £100 PDA Specification: WiFi Bluetooth USB Host Compact Flash Slot

19. Recent Advances Thermal imagery, cost £300-£30K

20. Self Study ► Take time to examine the Glossary of Terms provided on the following web site: www.skf.com/aptitudexchange/glossary.ht ml www.skf.com/aptitudexchange/glossary.ht ml ► Next week: Risk in project management. Alan Stafford Design in maintenance. Dave Knapton