When it comes to maintenance, most industries resort only to traditional preventive, predictive and corrective maintenance. Also, although the maintenance team actually believes they have reached their goals, a maintenance program based exclusively on time is not perfect.
Excessive maintenance or the lack of it end up being inefficient for the problems in a production line. Companies spend extra money on equipment that, often times, do not require maintenance and end up increasing the risk of breakdowns in others that are not often utilized.
That’s where Usage-Based Maintenance (UBM) comes in, translated to Portuguese as ‘Manutenção Baseada em Horas de Uso’. One technique that utilizes metrics and historical data to assess how much a certain item is used, and based on that, plans its maintenance. Preventing risks of excessive or insufficient repairs in any equipment.
In this article, we will talk about everything you need to know about UBM and how to implement it. Enjoy the reading!
What is Usage-Based Maintenance (UBM)?
The acronym UBM is a recent term, and it’s been gaining traction in the maintenance sector. This is due to the new techniques for maintenance management, asset management, and condition monitoring.
UBM consists of a maintenance strategy based on the successful use, and it focuses on maintenance planning based on the real use of the equipment.
Among others, these plans measure the main machine metrics, including:
- Limit temperature
- Downtime limit
- Equipment’s utilization time
From the collection of this data, it’s possible to schedule maintenance tasks. The opposite of a servicing plan based on the usage is a preventive maintenance plan based on time, following a defined schedule, regardless of how long a machine remains in operation during the day.
Instead of simply wondering how long the machine operated for, and when to execute maintenance, you can utilize the hour meter – calculated by the UBM, which informs the uptime (activity time) and/or downtime (inactivity time) of the machine – providing accuracy on when you should proceed with the maintenance.
Besides helping with the prediction, you also help with prevention. That is what we call maintenance based on usage hours.
For example: via generated reports, the industry is able to learn about the ideal conditions of the fluid and the assets. This way, the maintenance team can plan beforehand to identify possible failures that jeopardize the production performance and quality.
Learn the differences
In the list below, we consider three maintenance strategies:
- Failure-based maintenance (FBM) – when the repair happens after the occurrence of a failure;
- Usage-based maintenance (UBM) – it’s a type of preventive or predictive maintenance. After a given time of use by the machine, the service is executed;
- Condition-based maintenance (CBM) – considered a type of preventive maintenance. Executed when the condition does not meet the pre-determined criteria.
Among the main maintenance management models, such as RCM, TPM, TQMain, and others, we also include EUT from the Eindhoven University of Technology (in the Netherlands), which is applied in the following flowchart:
If the benefits of a strategy outweigh its costs, it then proves to be highly recommended. For old assets that have predictive indicators (optimizable), the inspection based on usage is the most recommended. For assets that don’t age with a predictive indicator, CBM is the most efficient through continuous monitoring.
After all, you cannot optimize the inspection time. This claim is justified only if the corrective maintenance is more costly than the preventive and the latter more costly than inspection. Corrective maintenance is almost always more costly than preventive maintenance owing to its unplanned nature.
What’s the Functionality of Maintenance Based on Usage?
Often times, the strategies used in preventive maintenance are approaches based on the calendar or on the equipment’s use.
The maintenance based on Usage Hours can be easily executed, scheduling maintenance activities in recurrent times. Combining the best of both worlds: preventive maintenance based on usage.
As mentioned earlier, maintenance based on hours of use is a type of preventive or predictive maintenance, changing according to the chosen strategy by the maintenance team. The team is triggered according to the real utilization of the assets, taking into account the average use daily, the specified due date, the operator’s diagnostics or the online monitoring system.
This maintenance is normally a better approach than the time triggers, once you have the best of both approaches: the maintenance is triggered by the estimated utilization, being easier to predict future occurrences.
The Steps of Usage-Based Maintenance
1. Definition of sensor limits
The usage limits are defined according to the type of machine that will be in operation, and normally follow the equipment’s cycles, such as, for instance, the time of use.
They can be defined based on historical data of similar assets or on the supplier’s recommendations.
2. Configuration in a system
The maintenance based on hours of use depends on the equipment’s record of utilization, therefore it needs to be configured in the machinery as well as in the computerized maintenance management system (CMMS).
The system’s platform is where the operator configures the Temperature Limits; the vibration maximum limit; data from the equipment’s components, such as bearings, belts or pulleys, machinery power, downtime limit, equipment’s time of use and other machinery data that will be collected by the monitoring sensor.
3. Data collection in a CMMS
All machine readings, no matter how many, go to the system. With the CMMS functionality, readings are recorded in a clear and streamlined way. Also, they are recorded in operational reports for verification.
The data will be used not only for the prevention of unexpected failures but also to generate valuable insights for the maintenance team.
Learn below about the 7 benefits of implementing the maintenance based on hours of use.
7 Benefits of Maintenance Based on Hours of Use
1. Increased equipment lifespan
All machines wear out over time, which is natural. However, it’s not normal to accept frequent failures in the equipment and replace it after a short period of use. Even the natural wear and tear should be followed all the time by the maintenance team.
With the maintenance up-to-date, along with the online monitoring, the chances of increasing the equipment’s lifespan are higher. When both are kept on a regular basis, the lifespan tends to be longer, reducing the cost of acquisition of new machines.
2. Increased asset availability
Only with the time triggers, it’s very hard to predict when you will have to execute the maintenance of an asset.
Establishing a UBM maintenance strategy, you will have a guarantee that the assets are in operation and under safe conditions of operation.
With maintenance based on hours of use, you will know exactly what is happening to the machinery. This technique can help reduce unnecessary extra maintenance and maximize the asset’s availability.
3. Prevented unexpected breakdowns
You will receive alerts when any abnormality is identified in the asset. Taking into account the real utilization of the asset, the maintenance activities will be identified by the manager in any possible anomaly.
Relying on preventive maintenance readings instead of simply time is better because it is associated with the utilization of the asset instead of a random date.
4. More efficient data collection
Instead of complex spreadsheets, you will need an online monitoring system to follow the company’s critical machinery. The maintenance technicians will easily record the readings of the equipment when necessary.
Remember: Learning more about the extent to which the risks related to how each asset can impact your operation is crucial for the industry’s performance.
5. Less downtime
The failures generated due to errors in the maintenance schedule can cause significant losses to the company, especially financially.
With the implementation of UBM it’s possible to reduce failures, and/or identify them beforehand so that they don’t lead to unexpected downtime, ensuring the assets remain functioning in the most suitable way.
Implementing a maintenance program based on hours of use in your company can be an excellent way to reduce costs and the chance of unexpected breakdowns or production stops.
6. Making better decisions
Before the production line faces any damage or stop, the maintenance team will be alert, because through UBM they will receive automatic alerts and information about each asset’s health.
7. Assertive service orders for the routine maintenance
With preventive maintenance, issuing service orders has always been a manual process. With the online monitoring system, the maintenance routine becomes easy and practical, since this job will be done automatically, executing the maintenance activities, notifying those responsible for the maintenance.
How Do You Implement UBM?
Maintenance based on Hours of Use is a maintenance strategy based on the running time of a given asset and it is one of the main variables in maintenance management systems (CMMS).
With this tool, all members of the team have access to the assets in only one place, with total visibility of the assets.
In the image below, we explain the step-by-step to start using this essential tool:
What’s Next?
Usage-Based Maintenance can be a powerful tool for maintenance workers. In order to optimize and facilitate UBM in your industry, you must use the right tools. The most important? An online monitoring system.
To learn more about how this tool can be implemented in your company, contact one of our specialists about our CMMS’ features.
