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How can you optimize maintenance schedules for the lowest life cycle cost?

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Maintenance is a crucial aspect of plant engineering, as it affects the reliability, availability, performance, and safety of your equipment and processes. However, maintenance also comes with costs, such as labor, materials, downtime, and energy consumption. Therefore, optimizing your maintenance schedules for the lowest life cycle cost (LCC) is a key challenge and opportunity for plant engineers. In this article, we will discuss some strategies and tools that can help you achieve this goal.

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Diego Santos

Técnico mecanico III | Tissue | Engenheiro de Produ??o | Tissue Bracell Papéis
Sachin Kumar Sharma

Sr. Design Engineer
Torkild Pedersen

IPSE.DK, Owner

1 What is LCC?

LCC is the total cost of owning, operating, and maintaining an asset over its useful life. It includes the initial acquisition cost, the operating and maintenance costs, and the disposal or replacement cost. LCC analysis helps you compare different alternatives and make informed decisions based on the long-term implications of your choices. For example, you can use LCC to evaluate whether to repair or replace an asset, or whether to perform preventive or predictive maintenance.

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Sachin Kumar Sharma

Sr. Design Engineer
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Effective optimized use of previous data and previous learnings will be the key factor. And also use of AI which can use previous track records for reducing future errors and decisions.

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2 How to optimize maintenance schedules?

Optimizing your maintenance schedules means finding the optimal balance between the frequency, duration, and scope of maintenance activities, and the expected benefits and costs of each option. There are different approaches and methods that can help you achieve this, such as Reliability-centered maintenance (RCM), Condition-based maintenance (CBM), and Optimization models and algorithms. RCM is a systematic process that identifies the functions and failure modes of your assets, as well as the most effective maintenance strategies. CBM is a proactive approach that monitors the actual condition and performance of your assets to avoid unnecessary or premature maintenance. Optimization models and algorithms are mathematical tools that can help you optimize your maintenance schedules based on various objectives and constraints, such as minimizing LCC, maximizing availability, or meeting production targets. These models can incorporate various data sources and factors such as historical records, failure distributions, cost functions, and maintenance policies.

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Torkild Pedersen

IPSE.DK, Owner
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You cannot optimize maintenance schedules without the history and feedback from your equipment, first you must do the hard work of gathering data, preferably with CMMS software. With data on-hand you can foresee wear & breakdown patterns and act accordingly. With this and the plan for future production targets you can begin to optimize maintenance schedules. Prioritize bottle neck equipment high and have the needed parts in stock. Remember that not everything fits into a CMMS system, walk the floor, talk to the operators, and get feedback, take notes. They might just have a great idea to solve one of your problems.

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L Dian Iman Adiriyan

Accounting | Graphic Designer
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Maintenance optimization should be considered during the design phase, when flexibility exists regarding maintenance and operations related decisions (example: installed stand-by items vs. mobile spare parts, repair tiers and supply chains). In other words, during the design phase, the opportunity exists to optimize the sum of CAPEX and OPEX.

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3 What are the benefits of optimizing maintenance schedules?

Optimizing your maintenance schedules can bring you multiple benefits, such as reduced maintenance costs, increased production efficiency, and enhanced safety and environmental performance. By performing maintenance only when needed, you can save on labor, materials, and energy costs, as well as extend the life span of your assets. Additionally, you can minimize downtime and improve reliability to increase your output and quality while aligning your maintenance schedules with your production schedules. Furthermore, optimizing your maintenance schedule can help prevent or mitigate failures, reducing the risks of accidents, injuries, or emissions. This will also help you comply with regulatory standards and best practices.

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4 What are the challenges of optimizing maintenance schedules?

Optimizing your maintenance schedules is not a simple task, as it requires accurate and reliable data on your assets, such as their condition, performance, failure history, and maintenance history. Additionally, you need to consider the uncertainty and variability of your assets, such as their degradation, failure, and repair rates. Furthermore, you need to balance the trade-offs and constraints of your options, such as the costs and benefits, the risks and rewards, and the technical and operational feasibility. Collecting and managing data can be difficult if you have a large asset portfolio or lack adequate sensors, systems, or software. Predicting and modeling factors can be complex if you have limited or incomplete data or face dynamic conditions. Making decisions can be challenging if you have multiple objectives or limited resources.

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5 How to overcome the challenges of optimizing maintenance schedules?

To effectively optimize your maintenance schedules, you need to adopt a holistic and systematic approach. This includes implementing a data-driven culture, which involves investing in data collection and analysis tools and training your staff to use data effectively. Additionally, you should apply a risk-based perspective by using risk assessment and management tools, such as FMEA or FTA. Furthermore, it is important to collaborate and communicate with all relevant stakeholders, such as managers, engineers, operators, and technicians, by establishing clear roles and responsibilities and sharing information and feedback.

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Diego Santos

Técnico mecanico III | Tissue | Engenheiro de Produ??o | Tissue Bracell Papéis
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Essa ferramenta FMEA aplicado com uma Matriz de Criticidade te conduz a um caminho de itens críticos, onde investir ou n?o, trazendo uma redu??o de custo, e dirigindo suas a??es fora do achismo, e sim atravéz de análise técnica e sistêmica. Ferramentas assim conseguimos otimizar cronogramas e custo de vários setores dentro de uma organiza??o, desde projetos à opera??es em funcionamento.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Torkild Pedersen

IPSE.DK, Owner
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For plant and production managers, make sure to consult your maintenance supervisor or get external (non-partial) consultants for advice when buying new equipment. Any salesperson will promote their equipment with price and capacity as a sales point. Far too often I have seen new equipment running at 100% capacity most of the time and this is a no go if you want a production line to run problem free. If possible, consider having 2 pieces of equipment with the same output, it will lower the stress on the equipment and let you continue production even if one machine is down for some reason.

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How can you optimize maintenance schedules for the lowest life cycle cost?

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1 What is LCC?

2 How to optimize maintenance schedules?

3 What are the benefits of optimizing maintenance schedules?

4 What are the challenges of optimizing maintenance schedules?

5 How to overcome the challenges of optimizing maintenance schedules?

6 Here’s what else to consider

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