Introduction to Maintenance

SMJ 4812 Proj. Management & Maintenance Engrg. Sem.I 2003/2004

Imagine

MAS flight oeing !3! left "#IA at 2$00 %m All t&o engine'( h)*ra+lic ')'tem' &or,ing 2$22 %m e-%lo'ion 'hoo, %lane .+m/er 2 engine torn a%art( 2 'e%arate h)*ra+lic line' cea'e* to &or, In '%ite of maintenance &or,( engine 'till faile* Imagine ha0ing no maintenance ')'tem

 Maintenance

an* relia/ilit) i' im%ortant Maintenance an* %ro*+ct 1+alit) Maintenance an* %ro*+cti0it) Maintenance an* 'afet) Maintenance an* '+%%l) chain( JI2 3ail+re ca+'e *i'r+%tion( &a'te( acci*ent( incon0enience an* e-%en'i0e

 4%erator'

le'' a/le to *o re%air' them'el0e' Machine an* %ro*+ct fail+re can ha0e effect on com%an)5' o%eration an* %rofita/ilit) I*le &or,er'( facilit) #o''e' *+e to /rea,*o&n

3ail+re

3ail+re 6 ina/ilit) to %ro*+ce &or, in a%%ro%riate manner E1+i%ment / machine fail+re on %ro*+ction floor 6 &orn o+t /earing( %+m%( %re''+re lea,'( /ro,en 'haft( o0erheate* machine etc. E1+i%ment fail+re in office 6 fail+re of %o&er '+%%l)( air7con*itione* ')'tem( com%+ter net&or,( %hotoco%) machine 8ehicle fail+re 6 /ra,e( tran'mi''ion( engine( cooling ')'tem

Maintenance in Ser0ice In*+'tr)

9o'%ital :e'ta+rant' 2ran'%ort

com%anie'

an,' 9otel' an* re'ort' Sho%%ing mall' / retail ;a' 'tation

Maintenance in Man+fact+ring <om%anie'

Electronic A+tomoti0e Petrochemical' :efiner) 3+rnit+re <eramic' 3oo*

an* /e0erage'

Maintenance
All

action' nece''ar) for retaining an item( or re'toring to it( a 'er0icea/le con*ition( incl+*e 'er0icing( re%air( mo*ification( o0erha+l( in'%ection an* con*ition 0erification Increa'e a0aila/ilit) of a ')'tem "ee% ')'tem5' e1+i%ment in &or,ing or*er

=+e'tion>
?h)

*o &e nee* maintenance> ?hat are the co't' of *oing maintenance> ?hat are the co't' of not *oing maintenance> ?hat are the /enefit' of maintenance> 9o& can maintenance increa'e %rofita/ilit) of com%an)>

P+r%o'e of Maintenance
Attem%t

to ma-imi@e %erformance of %ro*+ction e1+i%ment efficientl) an* reg+larl) Pre0ent /rea,*o&n or fail+re' Minimi@e %ro*+ction lo'' from fail+re' Increa'e relia/ilit) of the o%erating ')'tem'

Princi%le 4/jecti0e' in Maintenance

2o achie0e %ro*+ct 1+alit) an* c+'tomer 'ati'faction thro+gh a*j+'te* an* 'er0ice* e1+i%ment Ma-imi@e +'ef+l life of e1+i%ment "ee% e1+i%ment 'afe an* %re0ent 'afet) ha@ar*' Minimi@e fre1+enc) an* 'e0erit) of interr+%tion' Ma-imi@e %ro*+ction ca%acit) 6 thro+gh high +tili@ation of facilit)

Pro/lem' in Maintenance

#ac, of management attention to maintenance #ittle %artici%ation /) acco+nting in anal)@ing an* re%orting co't' Aiffic+ltie' in a%%l)ing 1+antitati0e anal)'i' Aiffic+ltie' in o/taining time an* co't e'timate' for maintenance &or,' Aiffic+ltie' in mea'+ring %erformance

Pro/lem' E-i't A+e 2o$

3ail+re to *e0elo% &ritten o/jecti0e' an* %olic) Ina*e1+ate /+*getar) control Ina*e1+ate control %roce*+re' for &or, or*er( 'er0ice re1+e't' etc. Infre1+ent +'e of 'tan*ar*' 2o control maintenance &or, A/'ence of co't re%ort' to ai* maintenance %lanning an* control ')'tem

Maintenance 4/jecti0e'
M+'t

/e con'i'tent &ith the goal' of %ro*+ction Bco't( 1+alit)( *eli0er)( 'afet)C M+'t /e com%rehen'i0e an* incl+*e '%ecific re'%on'i/ilitie'

Maintenance <o't'
<o't

to re%lace or re%air #o''e' of o+t%+t Aela)e* 'hi%ment Scra% an* re&or,

Types of Maintenance

Maintenance ma) /e cla''ifie* into fo+r categorie'$ B'ome a+thor' %refer three categorie'7 'che*+le* an* %re0enti0e maintenance' are merge*C <orrecti0e or rea,*o&n maintenance Sche*+le* maintenance Pre0enti0e maintenance Pre*icti0e B<on*ition7/a'e*C maintenance

Corrective or Breakdown Maintenance

<orrecti0e or rea,*o&n maintenance im%lie' that re%air' are ma*e after the e1+i%ment i' faile* an* can not %erform it' normal f+nction an)more =+ite j+'tifie* in 'mall factorie' &here$
6 Ao&n time' are non7critical an* re%air co't' are le'' than other t)%e of maintenance 6 3inancial j+'tification for 'che*+ling are not felt

Disadvantages of Corrective Maintenance

rea,*o&n generall) occ+r' ina%%ro%riate time' lea*ing to %oor an* h+rrie* maintenance E-ce''i0e *ela) in %ro*+ction & re*+ce' o+t%+t 3a'ter %lant *eterioration Increa'e' chance' of acci*ent' an* le'' 'afet) for /oth &or,er' an* machine' More '%oilt material' Airect lo'' of %rofit <an not /e em%lo)e* for e1+i%ment' reg+late* /) 'tat+tor) %ro0i'ion' e.g. crane'( lift an* hoi't' etc

Scheduled Maintenance

Sche*+le* maintenance i' a 'titch7in7time %roce*+re an* incor%orate' 6 in'%ection 6 l+/rication 6 re%air an* o0erha+l of e1+i%ment' If neglecte* can re'+lt in /rea,*o&n ;enerall) follo&e* for$ 6 o0erha+ling of machine' 6 changing of hea0) e1+i%ment oil' 6 cleaning of &ater an* other tan,' etc.

Preventive Maintenance (PM)

Princi%le

6 DPre0ention i' /etter than c+reE Proce*+re 7 Stitch7in7time It

6 locate' &ea, '%ot' of machiner) an* e1+i%ment' 6 %ro0i*e' them %erio*ic/'che*+le* in'%ection' an* minor re%air' to re*+ce the *anger of +nantici%ate* /rea,*o&n'

<an*i*ate' for Pre0enti0e Maintenance

!re"uency of !ailure #ood candidates have ore nor al distri$ution with low varia$ility

Mean Ti e Between !ailure (MTB!)

%dvantages of PM
A*0antage'$

6:e*+ce' /rea, *o&n an* there/) *o&n time 6#a'' o**7time re%air an* re*+ce' o0er time of cre&' 6;reater 'afet) of &or,er' 6#o&er maintenance an* re%air co't' 6#e'' 'tan*7/) e1+i%ment' an* '%are %art' 6 etter %ro*+ct 1+alit) an* fe&er re&or,' an* 'cra%' 6Increa'e' %lant life 6Increa'e' chance' to get %ro*+ction incenti0e /on+'

Predictive (Condition&$ased) Maintenance

In

%re*icti0e maintenance( machiner) con*ition' are %erio*icall) monitore* an* thi' ena/le' the maintenance cre&' to ta,e timel) action'( '+ch a' machine a*j+'tment( re%air or o0erha+l ma,e' +'e of h+man 'en'e an* other 'en'iti0e in'tr+ment'( '+ch a'
6a+*io ga+ge( 0i/ration anal)@er( am%lit+*e meter( %re''+re( tem%erat+re an* re'i'tance 'train ga+ge' etc.

It

Predictive Maintenance (Contd')

Fn+'+al

'o+n*' coming o+t of a rotating e1+i%ment %re*ict' a tro+/le An e-ce''i0el) hot electric ca/le %re*ict' a tro+/le Sim%le han* to+ch can %oint o+t man) +n+'+al e1+i%ment con*ition' an* th+' %re*ict' a tro+/le

Maintenance <o't'
Cost

Breakdown Cost Maintenance Co it ent

Maintenance <o't'
Cost

PM Cost Breakdown Cost Maintenance Co it ent

Maintenance <o't'
Cost Total Maintenance Cost

PM Cost Breakdown Cost Maintenance Co it ent

Maintenance <o't'
Cost Total Maintenance Cost

PM Cost Breakdown Cost (pti al Maintenance Co it ent

Deter ining the Si)e of *epair Crews

Pro/lem$ A factor) ha' 200 machine' an* the maintenance engineer '+%er0i'e' the re%air cre&' &ho re%air malf+nctioning machine'. 2he maintenance %olic) i' to re%air the /ro,en *o&n machine an* /ring /ac, in %ro*+ction &ithin 2 ho+r' on the a0erage. If a0erage /rea,*o&n rate i' 3.G machine'/ho+r an* each re%air cre& can re%air 0.2G machine %er ho+r on the a0erage. 9o& man) re%air cre&' are re1+ire* >

Sol+tion
2he form+la for a0erage re%air rate BC i' 1 t' H 7777777777 or H I 1/ t' 7 ?here H re%air rate H arri0al rate of malf+nctioning machine' t' H a0erage time arri0al' in the ')'tem :e1+ire* a0erage re%air rate H 3.G I 1 / 2 H 4 machine' / ho+r .o. of <re&' H machine'/ho+r a cre& can re%air H 4 0.2G H 1J re%air cre&' re1+ire*