Maintenance Management

WHY DO WE MAINTAIN?

To minimize equipment malfunction

Equipment Malfunctions
Equipment malfunctions have a direct impact on: Production capacity Production costs Product and service quality Employee or customer safety Customer satisfaction

Maintenance Departments
A maintenance manager typically is a plant engineer who reports to a plant or manufacturing manager Maintenance departments are usually split into two groups: Buildings and Grounds Equipment

Maintenance Activities
Repairs
Repair activities are reactive. Breakdowns and malfunctions typically occur when equipment is in use. Standby machines and parts can speed repairs.

Preventive Maintenance (PM)

Regularly scheduled inspections are performed. PM activities are performed before equipment fails. PM is usually performed during idle periods.

Tradeoff Between Repairs and PM

At minimum level of PM, it is a remedial policy
fix machines only when they break the cost of breakdowns, interruptions to production, and repairs is high

As the PM effort is increased, breakdown and repair cost is reduced At some point, the total maintenance cost (PM, breakdown, and repair) reach a minimum

Tradeoff Between Repairs and PM

Annual Cost ($)
Minimum Total Maintenance Cost

Minimum Level of Preventive Maintenance

Total Maintenance Costs Preventive Maintenance Cost Breakdown and Repair Cost

Degree of Preventive Maintenance

Repair Crews and Standby Machines

Repairs often performed on an emergency basis to:
Minimize interruptions to production Correct unsafe working conditions Improve product/service quality

In emergency situations:
Specialists may work overtime Supervisor/engineers are nearby to collaborate Standby machines may be quickly put in operation

How Speedy Should Repairs Be?

Cost ($) Minimum Total Cost of Repairs

Total Costs of Repairs Cost of Repair Crews & Shops, Spare Parts, and Standby Machines Cost of Interruptions to Production

Slow

Speed of Making Repairs

Fast

Types of Maintenance System

-Reactive Maintenance -Preventive Maintenance

-Predictive Maintenance
-Reliability Maintenance

-Total Productive Maintenance

Reactive Maintenance
Carry out maintenance when the asset/ equipment breaks down
Maintenance cost is the highest

Preventive Maintenance

--Maintenance actions are carried out on a time or machine-run-based schedule that detect, preclude or mitigate degradation of component or system

Predictive Maintenance
Measurements are carried out that detect the onset of a degradation mechanism, thereby allowing casual stressors to be eliminated or controlled prior to any significant deterioration in the component physical state.

Reliability Centered Maintenance

A process used to determine the maintenance requirement of any physical asset in the operating context Will involve -< 10 % Reactive Maintenance

-25-35 % Preventive Maintenance

-45 55 % Predictive Maintenance

TPM Total Productive Maintenance

-This can be also called as Total Production Maintenance. This correctly signifies its concept. It involves in ensuring that the required product is produced using the asset by properly maintaining the asset and with little wastage. -It involves the maintenance of the asset as well processes to reduce wastage production by using 5S, PokaYoke, SMED etc. -It goes beyond traditional maintenance functions.

Corrective Maintenance
Take measures to find out the root cause which causes frequent breakdowns. Most of the time, asset designers had not anticipated these causes What type of maintenance practice that you follow will depend on the type of industry you are working in. It will be a mixture of the different practices enumerated earlier.

Some Types of Industries

Aircraft Operation Power Plant Operation Chemical /Refineries (some of these can be continuous processes) Multiple types of asset industry for example, automobile manufacturing industry

Challenges in Maintenance Management

Status of maintenance in the hierarchy as prevalent
in a company Normally Maintenance Dept/ staff are on the fringe of the main management in many companies, maint. Dept./maint. staff may be considered as necessary evil Status of the staff in the hierarchy may not be high;

however it should not dishearten you.

Challenges in Maintenance Management

Maintenance engineer is like a doctor. Health of Maintenance Engineer

challenges in multi-type asset industry like automobile manufacturing industry

Challenges in Maintenance
Mechanical, Electrical and Electronic maintenance in Machine Shops Foundry Press Shop Body Shop and Paint Shop Assembly Shop Utilities like water, gas and air

The Challenges involved

High breakdown Unorganized Maintenance Preparation of Asset History Development expertise in mechatronic
Experiences Drawings RTF Failures at one of the plants Water line instead of air line Unscheduled power cuts Voltage fluctuations Failure of computer systems of machines