An approach to maintenance optimization where safety issues are important

The starting point for this paper is a traditional approach to maintenance optimization where an object function is used for optimizing maintenance intervals. The object function reflects maintenance cost, cost of loss of production/services, as well as safety costs, and is based on a classical cost–benefit analysis approach where a value of prevented fatality (VPF) is used to weight the importance of safety. However, the rationale for such an approach could be questioned. What is the meaning of such a VPF figure, and is it sufficient to reflect the importance of safety by calculating the expected fatality loss VPF and potential loss of lives (PLL) as being done in the cost–benefit analyses? Should the VPF be the same number for all type of accidents, or should it be increased in case of multiple fatality accidents to reflect gross accident aversion?In this paper, these issues are discussed. We conclude that we have to see beyond the expected values in situations with high safety impacts. A framework is presented which opens up for a broader decision basis, covering considerations on the potential for gross accidents, the type of uncertainties and lack of knowledge of important risk influencing factors. Decisions with a high safety impact are moved from the maintenance department to the “Safety Board” for a broader discussion. In this way, we avoid that the object function is used in a mechanical way to optimize the maintenance and important safety-related decisions are made implicit and outside the normal arena for safety decisions, e.g. outside the traditional “Safety Board”.A case study from the Norwegian railways is used to illustrate the discussions.