ME141239 - Maintenance Management Document of

Major Maintenance
Hadits Shofar Fauzi Business Process
4212100034
Marine Engineering Department PT. Shafar Shipping (Persero)
Table of Content

Cover.. 1
Table of Content.... 2
Introductions...... 3
Background.... 3
Objectives........... 3
Abbreviations...... 3
References........ 3
Major Maintenance Business Process........ 4
A. Maintenance Programs. 5
B. Preventive Maintenance.. 5
B.1 Annual Survey. 5
B.2 Intermediate Survey.. 5
B.3 Special Survey. 6
C. Predictive Maintenance 6
C.1 Equipment Monitoring. 6
D. Routine Check.. 6
E. Reporting. 6
E.1 Failure Report.. 7
F. Corrective Maintenance 7
F.1 Immediate Maintenance. 7
F.2 First Line Maintenance. 7
F.3 Deferred Maintenance. 7
G. Improvement 7
G.1 Analysis 7
G.2 RAM Analysis.. 8
H. Database Recorded.. 8
Appendix A (informative) General Requirements for Surveys (BKI Vol.1 Section 3).. 9

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Background
The term maintenance typically means sustaining or preserving a desired condition or level
of performance. However, in some plant, maintenance means fixing things that break doing
the needed repairs.
Maintenance management is essential to the success of any organization because a poorly
organized maintenance program can bring the entire company to a halt. Inconsistencies in
equipment lead to variability in product characteristics and result in defective parts that fail
to meet the established specifications. Beyond just preventing break downs, it is necessary to
keep equipment operating within specifications that will produce high level of quality.
Dependability of service is one of the performance measures by which a company can
distinguish itself from others.
To establish a competitive edge and to provide good customer service, companies must have
reliable equipment that will respond to customer demands when needed. Equipment must
be kept in reliable condition without costly work stoppage and down time due to repairs, if
the company is to remain productive and competitive, so the application of maintenance
business process can be used as a consideration for purposing good maintenance. It can be
used to propose a better action and classify which equipment that needed more
maintenance and also analyze the result scheme of RAM analysis.

Objectives
The purpose of this document is to provide requirements and guidelines for
maintenance major process classifications
maintenance resources optimizations
how to use analysis to get better result for maintenance

Abbreviations
RAM Reliability, Availability, and Maintainability
KPI Key Performance Indicator

References
NORSOK STANDARD Z-008
DIN EN 13306:2008
Wireman, Terry. 2004.
BKI 2014 Vol. 1 Section 3
Risk Based Maintenance and Consequence Classification
Maintenance Terminology
Benchmarking BEST Practices in Maintenance
Management
Surveys General Requirements

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Major Maintenance Business Process

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A.
Maintenance Programs
Failure modes, failure mechanisms and failure causes that can have a significant effect on
safety and production. The maintenance program includes maintenance interval and written
procedures for maintaining, testing, and preparing the various components within the plant.
This activity will typically involve the following:
Performing consequence classification for functions. The consequence class is
inherited by the equipment relevant for the function;
For equipment representing high consequence in case of failure, the failure mode,
failure cause and the connected maintenance program should be developed,
documented and made traceable;
Safety barriers and/or safety functions should be identified, reliability requirements
defined for the functions, and a testing program to maintain the functionality should
be developed;
Criteria for when the maintenance program are to be updated based on time,
experienced failures or similar should be defined. In particular failures of safety
critical systems shall be analyzed and the program updated on a regular basis.

B.
Preventive Maintenance
Maintenance carried out at predetermined intervals or according to prescribed criteria and
intended to reduce the probability of failure or the degradation of the functioning of an item.

B.1
Annual Survey
Annual surveys are to be conducted each repetition year after the ship is launched, the 5-
year survey cycle. Annual survey may be conducted 3 months before or after the due date.
And if within 6 months of the annual survey has not been done, then the certification of
classification are not applicable. (See Appendix A)

B.2
Intermediate Survey
The survey has conducted during / between periods of the second and the third annual
survey. And can be started very early point in the 3 months prior to the second year of the
ship. During the intermediate surveys can include the things needed, anytime up to 3 months
after the third year of the ship. Classification will be automatically void if the intermediate
survey has not been resolved, and there is no tolerance for it. (See Appendix A)

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B.3
Special Survey
All ships in the class at LR Discount survey should also be done in accordance with the
requirements given in Chapter 3. The survey was conducted at intervals of 5 years. The first 5
years from the date of the vessel is completed / submitted from the ship builder. And the
next 5 years from the date of the previous Special Survey. Consideration may be given at the
discretion of the committee to any exceptional circumstances which allow the extension of
the classification of the hull to a maximum of three months beyond the fifth year. If the
extension is approved in the next period the hull classification will be calculated from the due
date of Special Survey before being given an extension. (See Appendix A)

C.
Predictive Maintenance
Maintenance allowed failures to be forecasted through analysis of the equipments
condition. The analysis are generally conducted through some form of trending of a
parameter. Predictive maintenance allowed the equipment to be repaired out of production
scheduled time, thereby removing one of the largest factors from downtime cost. The
equipment service level will be very high under predictive maintenance.

C.1
Equipment Monitoring
Activity, performed either manually or automatically, intended to measure at predetermined
intervals the characteristics and parameters of the actual state of an item,

NOTE 1 Monitoring is distinguished from inspection in that it is used to evaluate any changes in the
parameters of the item with time.
NOTE 2 Monitoring may be continuous, over time interval or after a given number of operations.
NOTE 3 Monitoring is usually carried out in the operating state.

D.
Routine Check
Maintenance that is to be carried out by ships crew onboard under the support of Marine
Section office and Maintenance Department, which can be routinely carried out outside the
docking schedule.

E.
Reporting
Another way to looked at maintenance organizations. Maintenance organizations are usually
using several of structures, including the maintenance-centric model, the production-centric
model, and the engineering-centric model.

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E.1
Failure Report
All maintenance personnel in the plant are reported through a maintenance manager. If the
organization is larger, there may be other levels of supervisors reporting to the maintenance
manager. The indicated failure then reported to carry out through corrective maintenance.

F.
Corrective Maintenance
Maintenance carried out after fault recognition and intended to put an item into a state in
which it can perform a required function.

F.1
Immediate Maintenance
Corrective Maintenance which should be carried out without delay after a fault has been
detected to avoid unacceptable consequences.

F.2
First Line Maintenance
Maintenance carried out on the item whilst it is operating and without impact on its
performance. This maintenance can be characterized by simple actions.

F.3
Deferred Maintenance
Corrective maintenance which is not immediately carried out after fault detection but is
delayed in accordance with given rules.

G.
Improvement
Final implementation of the actions identified, as well as measurement of the effect via KPIs
and equipment reliability data. The identified improvements, actions should be implemented
and the effect should be monitored.

G.1
Analysis
This activity involved carry out analysis of historical maintenance data, and unwanted
incidents related to maintenance, e.g. trend analysis, root cause failure analysis. Further the
information should be evaluated and implement actions suggested based on the conducted
analysis. This will typically involve the following:

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a. A defined analysis process shall be in place addressing trigger values, analysis technique
and responsibilities. The work shall be documented and monitored;
b. The analysis process should include evaluation of maintenance effectiveness, i.e. to what
extend the maintenance program are handling the risks and performance requirements
for individual systems or key components;

G.2
RAM Analysis
Improvement method for analyzing Reliability, Availability, and Maintainability to deliver risk
level and performance of maintenance.
Reliability: The ability of an item to perform a required function under given conditions for a
given time interval.
Availability: The ability to be in a state to perform as required, under given conditions, at a
given instant or over a given time interval.
Maintainability: The ability of an item under given conditions of use, to be retained in, or
restored to, a state in which it can perform a required function, when maintenance
is performed under given conditions and using stated procedures and resources.

H.
Database Recorded
Data collected from inspection records, manual books, and/or classification societys rules.
Data recorded into database recording system (usually CMMS) in order to be a part of
consideration for the next maintenance programs.

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