Risk Based Maintenance (RBM) differs from ordinary maintenance because it focuses on defining priorities in responding to the maintenance needs of the most risk-sensitive machinery.
In other words, the RBM aims to direct resources first of all to plants which, without adequate maintenance, can cause damage and therefore higher costs, compared to others.
This type of maintenance determines the cheapest way to distribute resources, in order to repair a system or minimize the risk of failure, with greater benefits and protection for employees, resources and the entire company.
Now let’s see together exactly how this type of maintenance works, what benefits derive from it and why and which companies need it.
WHICH COMPANIES BENEFIT THE MOST FROM RISK-BASED MAINTENANCE?
Assuming that all companies benefit from this type of maintenance, it is evident that for some companies it becomes a real need to optimize its operation.
- Companies that have limited numbers of high-use machinery or vehicles: think for example of a company that only has a truck for weekly deliveries and the difficulties it would face if this vehicle breaks down. Risk-Based Maintenance contributes greatly to preventing unexpected failures in machinery or confined systems.
- For companies using very expensive machinery, maintenance ensures that high levels of performance are maintained.
- Companies that have limited resources to employ in maintenance and repair.
MAIN ADVANTAGES OF RISK BASED MAINTENANCE
Risk Based Maintenance is important because:
- Identify problems before they occur: consequently, by planning maintenance, downtime is minimized.
- By avoiding emergency maintenance, in the event of a machinery malfunction, time and costs are reduced to diagnose the failure and replace the equipment. It is estimated that unscheduled maintenance typically costs three to five times more than when it is planned.
- The system is safer and more efficient.
- With RBM, the useful life cycle of company resources is extended.
- It positively contributes to the reputation of companies and prevents the negative impact of failure and interruption of production on customers and the supply chain.
PHASES OF THE RBM PROGRAM
- Data collection and resource inventory.
- Risk assessment: assign a “probability of failure” (Probability of Failure POF) to each asset, based on knowledge of the life cycle of the asset and its degradation. The probability of failure does not depend only on the weather, but also on the climatic and environmental conditions of the place where the Asset is located: for example, resources located in humid or dusty places may require more maintenance and may be more likely to deteriorate. The POF is provided through conservation and prevention.
- Establish what is the consequence of failure (Consequences of Failure COF), i.e. quantify the damage in economic and production terms resulting from the failure and plan the recovery or repair of the asset.
- Create risk-based maintenance plans and implement them and repeat the control cycle regularly, according to the specific needs of the company.
Progepi supports companies in creating efficient plans for Risk-Based Maintenance, call for any need!