Support your business goals with
SKF Maintenance Strategy Review
Every company takes care of their production assets through maintenance executed either by
maintenance personnel, operators (asset care programmes) or through subcontractors.
These maintenance tasks are often part of maintenance plans Most maintenance plans are developed historically by using
and kept in Computerized Maintenance Management Systems OEM or supplier recommendations enhanced by the experi-
(CMMS) or Enterprise Asset Management (EAM) systems e.g. ence of the maintenance people. But are these maintenance
SAP PM, Maximo, ApiPro. tasks the right tasks and the right strategy to fulfil your
business goals and mitigate the risk of critical equipment
Still companies often face a lot of unplanned downtime, Stops failing to fulfil its intended function?
in production lines lead to low production output and high
maintenance costs. How can we break this downward trend? The SKF Maintenance Strategy Review process follows a set
of logical steps to identify the right maintenance strategy and
maintenance tasks to reach your business goals.
SKF Maintenance Strategy Review, process overview
Objectives Set up criticality matrix Functions
Failure modes
P&ID Selection of critical assets
Failure causes
Failure interval
Failure mode, effect and
criticality analysis
Failure consequences
Criticality analysis
Failure characteristics analysis
Cost-benefits consideration
Maintenance strategy selection
RTF FFM CBM SM MOD Legislation
Task selection Spare part decision
Task comparison Existing PM programme
Work packages
Implementation
Continuous improvement
Business goals and
risk matrix
Business goals are reflected in a risk matrix containing the company’s business drivers and
associated risk levels, as well as the probability of the risk occurring. Typical drivers are safety,
environment, production loss and maintenance cost.
Example of a Risk Matrix
Effect of failure Probability of failure
Category Safety Environment Production Repair (1) (2) (3) (4) (5)
Very Unlikely Possible Likely Very
unlikely >5 > 1 year >1 likely
> 10 years and and ≤ 5 years month and ≤ 1 month
years ≤ 10 years ≤ 12 months
E. Negligible risk No impact Loss< 1 hour Cost< E1 E2 E3 E4 E5
Negligible €1.000, -
D. First aid Low impact Loss< 1 day €1000,- < cost D1 D2 D3 D4 D5
Low < €10.000, -
C. Doctor treatment Within plant Loss 1- 3 days €10.000, - < C1 C2 C3 C4 C5
Medium cost<
€100.000,-
B. Serious accidents Within site Loss> 3 days €100.000, B1 B2 B3 B4 B5
High -<
cost<
€500.000,-
A. Genuine risk for Outside site Shutdown of Cost> A1 A2 A3 A4 A5
Catastrophic human life several plants €500.000, -
After the management team has built a risk matrix, the When the function is known the functional failure is also
acceptable risks are defined and the foundation for the known as this is just the opposite of the function.
maintenance tasks are set.
Now you take the asset and determine the risks that occur if
The next step is to take each maintainable item or asset to this asset fails. Is there a significant impact on one of the
define the function it has in your production line. The function business drivers? If there is no risk, then typically the strategy
is important because it defines what you expect from this would be “Run to Failure (RtF) which implies that no
asset. You can imagine that the function of a pump in your maintenance has to be done. However, if there is a risk, the
production line is different from that of the same pump maintenance strategy would be determined following the logic
installed as standby if the prime pump fails to fulfil its of a decision tree.
function.
2
Decision tree to determine
the maintenance strategy
The decision tree now determines the maintenance strategy: Scheduled Maintenance,
Condition-Based Maintenance, Failure Finding Maintenance or a Modification.
Decision tree for Maintenance Strategy selection
Failure (input decision tree)
Yes No
Hidden failure?
No Yes No Yes
Condition indicator available? Critical failure?
Yes No
Failure age related
No Yes
Condition indicator available?
No Yes
Constant failure interval?
FFM CBM RTF SM CBM SM MOD
(Failure (Condition- (Run To (Scheduled (Condition- (Scheduled (Modification)
Finding Based Failure) Maintenance) Based Maintenance)
Maintenance) Maintenance) Maintenance)
Maintenance tasks Examples of tasks:
The tasks can be selected from a database, historical prac- • Lubrication
tices, recommendations from suppliers or asset specialists. • Cleaning
SKF has a large database where equipment failure modes, • Inspections
failure causes, tasks and their intervals are specified, making • Calibration
an SKF Maintenance Strategy Review easy. This ensures a • Vibration monitoring
speedy process. • Thermography
• Ultrasound
Current maintenance tasks are naturally taken into account • Checks
when enhancing the existing plan to meet business goals.
For each task we agree who will do the tasks e.g. mechanics,
Another important element of following the SKF Maintenance electricians, operators, lubricators or cleaners. When tasks are
Strategy Review process is the identification of critical spares. assigned to operators, you automatically move towards
If there are no tasks which mitigate the full risk, a spare part is operator involvement or operator driven reliability (ODR).
the solution. This spare part now becomes critical. There is a
documented process for defining the critical spares and spares If you have an ageing workforce and you want to capture the
needed for preventive maintenance, eliminating the need for valuable knowledge of these experts, documenting the
qualified guesswork. The results of the SKF Maintenance thought process in the system makes your company less
Strategy Review are the right maintenance tasks. vulnerable when these people retire.
3
Software Tool – AMST
This whole process can be documented in the tool developed When the tasks are implemented in the maintenance man-
by SKF and called Asset Management Support Tool (AMST). agement system, they are ready for the planning stage and
The tasks and maintenance plan can be uploaded from AMST the journey towards reducing unplanned downtime can begin.
into the customer maintenance management system.
TCO OEE
Programme
characteristic STABILIZING OPTIMIZING
Maintenance
maturity Firefighting Maintaining Promoting Innovating
Driver Breakdowns Avoid failure Uptime Growth
Reward Overtime heroes No surprises Competitive advantage Efficiency optimization
Behaviour Responding Planning Disciplined organization Organized learning
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© SKF Group 2019
The contents of this publication are the copyright of the publisher and may not be reproduced (even
extracts) unless prior written permission is granted. Every care has been taken to ensure the accuracy
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PUB SR/P8 18396 EN · April 2019
