Manufacturing Operations · Maintenance · Component
The maintenance regime
Which approach applies to which asset — preventive, condition-based or run-to-failure — chosen on consequence rather than habit.
The deliverable
What it is
Preventive scheduling suits equipment that wears predictably; condition monitoring suits equipment that gives warning; run-to-failure is legitimate where consequence is low and the spare is on the shelf.
Applying one regime to everything is the common failure and it is expensive in both directions — over-maintaining the trivial and under-maintaining the critical.
One level in
What it is made of
Each element is a constituent part of the component. Follow one to see the attributes it carries.
The failure behaviour
How the asset actually fails — with wear, randomly, or with warning.
3 attributes: Failure pattern · Gives warning · Warning period
LearnThe consequence
What failure would actually cost.
3 attributes: Failure cost · Consequence type · At constraint
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Time-based maintenance on a randomly failing asset achieves nothing and can introduce faults that would not have occurred.
The other components in maintenance
The schedule
Planned work with protected windows — because a window that is always surrendered to production is not a schedule.
LearnThe downtime record
Unplanned stops by cause, so that repeats become visible — because a repeated cause is a design problem rather than a maintenance one.
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