ABSTRACT DOCTORAL THESIS OF MARC GARDELLA IN ENGLISH

The doctoral thesis that happens to us, shows the basic assumptions of the research on 
the introduction of preventive and predictive maintenance industries process, thanks to 
the development and customization of the RCM of the AMFEC methodology. The 
RCM, methodology used to determine maintenance activities reactive and proactive in 
order to optimize the reliability of the industrial assets. 

 
The background of the doctoral thesis says that the methodology RCM, serves to 
identify the reactive and proactive, peacekeeping activities in order to optimize the 
reliability of industrial assets. It is based on the work of John Moubray, where the 
introduction of RCM is based on seven questions. Methods of calculation of criticalities 
currently reflected in current study denote the opportunity to develop methods of 
calculation where many variables are taken into account. Risk (NPR) for each mode of 
failure, weighting number comes severity, frequency of failures and discoverability be 
calculated based on three parameters, being usually rated from 1 to 10, but invariant to 
variations of technical parameters and operation. Maintenance plans but well defined by 
the work of experts, develop depending on types of equipment, types of maintenance 
and criticality of NPR failure modes in sight. Studies of management, indicators are 
spacious and very well developed, although for the detection of repetition of incidents in 
the corrective maintenance, requiring a definition or development. 

 
The main objective of this study is to assist the implementation of a method of technical 
and economic management of assets, based on the current implementation of RCM, 
Preventive Maintenance and management indicators and define a method to implement 
preventive and predictive maintenance, control incidents, costs, and implement 
technical solutions; thus, optimizing the management of maintenance in process 
industries . The doctoral thesis aims to define the RCM according to John Moubray; 
methodology definition of a protocol for the implementation of the improvements made 
to the RCM the AMFEC and preventive maintenance methodology and predictive; 
structure study by groups of systems and systems assets or computers; develop 
comprehensive methods of calculation of criticalities, systematize the modes to 
facilitate AMFEC bug database's; develop a system of assessment of the risk of failure 
(NPR) mode specifically for computer and also variables depending on changes in 
technical variables and operational typologies; designing measuring frequency bug by 
typologies of equipment systems facilitate the design plan preventive maintenance 
interventions, types of equipment and frequencies of performance; and two new 
indicators management, number of incidents and costs associated to control repetition 
of his appearance in assets of industries of corrective maintenance processes 
definition. 

 
The methodology adopted in this study is based on the analysis of parts that encompass 
the RCM; method as well as, maintenance, preventive maintenance planning and 
management indicators. Each of these parties, and in particular more relevant parts of 
the RCM, calculation criticalities, failures and NPR; modes have been used to 
implement a system of asset management, achieving successful results, but denoting 
opportunities for improvement in each of these parts. This is when improvements in 
each of these parts have been developed and integrated forming the present thesis. In 
addition, to facilitate understanding of the improvements made, for each development 
examples with real case studies from the process industry. 

 
A detailed example AMFEC application and making a group matrix motor-pump current 
methodology RCM has shown. Set a protocol on a diagram, on the integration of both 
improvements to RCM, such as preventive maintenance and management, indicators 
and a feedback protocol adjusting what it should be if the results are improved. Set a 
way of structuring assets by groups of systems, showing an example with 11 levels, to 
facilitate the implantation of contributed improvements in industrial sectors, 
geographical areas, types of processes, types of equipment and supplies, and thereby 
have a clear identity study asset when you begin to implement improvements. 

 
It designed three methods of calculation of criticalities, one depending on legal issues 
and results to take into account aspects governing a company industrial, but results of 
criticality catalogued as qualitative critical facilities, good points. Other according to 
operational aspects and impact levels emphasizing the importance of the impact on 
safety, environmental protection, production and maintenance. The third and last is 
according to characteristics of the equipment, where countless variables technical, 
legal, economic, productive, etc., which have interaction with assets of study, and this 
method which results in more reliable since it can be weighted vary the number of 
variables used depending on complexity of facilities study and accuracy in the result to 
be obtained. 

 
It defined database failures on three levels, modes for 4 types of equipment rotary 
machines, deposits, exchange of heat and valves. Completed a study in-depth the NPR 
with different definitions of severity and frequency of faults; as well as, developed two 
ways of assessing the NPR macroscopic and microscopic, and show how varies the 
NPR depending on changes in technical variables and operation. Different weighting 
parameters and ranges of NPR, serve to differentiate its valuation according to types of 
computers. 
 

Set the types of equipment, maintenance and criticality of NPR, strategic maintenance 
plan showing frequencies of peacekeeping intervention. Checking information plan 
routes frequency areas or industrial plants and the economic valuation of each 
maintenance activity has been calculating each path of preventive maintenance by 
frequency, areas or zones and types of equipment. This indicates a way of achieving 
results for comparison with the assigned maintenance budgets. 


Defining number of occurrence of a same incidence and associated cost indicator, 
could be performed box control incidents and the corrective maintenance costs. A case 
study real industry processes, types of equipment has been bombs and reactors. Also 
set a form of the organization information in industry processes, with multiple diagrams 
and schemes, to finish in the technical solution that closes the cycle. 

 
Conclusions set the RCM, preventive maintenance and predictive philosophy and 
management, indicators were found development needs of some of its parts. If 
provision of preventive and predictive maintenance in the matrix of decisions generally 
to the asset, it reduces the time to study, but is not as reliable as NPR by crash mode is 
the objective of this part of the RCM. Define a protocol implementation of 
improvements to the RCM method helps to visualize as it wants to work step by step, to 
achieve the desired results. It structuring assets in groups of systems, and systems 
defining similar characteristics, makes it easy to deploy more adequately RCM. 
 
The method of calculation of criticality by weighting features is more flexible and 
adaptable to any industrial environment, where can be used from a few tens of 
variables until some tens of thousands, as we want more or less precision; an example 
of this is a carpenter or a nuclear industry machinery criticality. AMFEC databases and 
the exhaustive study of NPR, bring improvements of considerable value to the RCM, 
methodology since apart from facilitating AMFEC clothing's, given variation of 
parameters in assets of process industries. 

 
The structuring of the activities of preventive and predictive maintenance plan strategic 
maintenance, the subsequent definition of routes and the calculation of costs associated 
with them, is a way to control the exploitation of the maintenance of an industrial 
environment with rigor. The definition of indicators to measure the repetition of incidents 
and their associated costs, facilitate observation teams with great presence in industry 
processes, economic and technical problems such as pumps and reactors.
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