Integration of maintenance systems

Abstract

Excellence in maintenance is imperative in highly competitive market because it resulted into minimum maintenance cost, high equipment effectiveness, maximum reliability of the system, high quality of the products, low delivery time, high flexibility, safety etc. Any maintenance system such as Total Productive Maintenance (TPM) or Reliability Centered Maintenance (RCM) or Condition Based Maintenance (CBM) alone cannot achieve the excellence in maintenance but its integration may do. In this paper, an integration of TPM, RCM and CBM is proposed with a maintenance policy to take advantage of their respective strengths. A continuously monitored system subject to degradation due to the imperfect maintenance, where a hybrid hazard rate based on the concept of age reduction factor and hazard rate increase factor to predict the evolution of the system reliability in different maintenance cycles has been assumed.A quantitative decision making model for an integrated maintenance system is derived in order to assess the performance of the proposed maintenance policy. Numerical examples of calculation of optimal preventive maintenance age x and preventive maintenance number N* for the given cost ratio of corrective replacement and predictive preventive maintenance are given.