MAINTENANCE MANAGEMENT

Prof. O.P. Gandhi

ITMMEC, IIT Delhi
The term maintenance means to keep the eqipment in operational condition or repair it
to its operational mode. Main o!"ecti#e of the maintenance is to ha#e increased
a#aila!ilit$ of prodction s$stems, %ith increased safet$ and optimi&ed cost. Maintenance
mana'ement in#ol#es mana'in' the fnctions of maintenance. Maintainin' eqipment in
the field has !een a challen'in' task since the !e'innin' of indstrial re#oltion. (ince
then, a si'nificant of pro'ress has !een made to maintain eqipment effecti#el$ in the
field. )s the en'ineerin' eqipment !ecomes sophisticated and e*pensi#e to prodce and
maintain, maintenance mana'ement has to face e#en more challen'in' sitations to
maintain effecti#el$ sch eqipments in indstrial en#ironment. This !rief lectre on
maintenance mana'ement incldes maintenance strate'ies, fnctions of maintenance
department, maintenance or'ani&ation and elements of maintenance mana'ement.
MAINTENANCE STRATEGIES OR OPTIONS
) maintenance strate'$ or option means a scheme for maintenance, i.e. an ela!orate and
s$stematic plan of maintenance action. +ollo%in' are the maintenance strate'ies ,-. that
are commonl$ applied in the plants.
/reakdo%n Maintenance or Operate to +ailre or 0nplanned Maintenance
Pre#enti#e or (chedled Maintenance
Predicti#e or Condition /ased Maintenance
Opportnit$ Maintenance
Desi'n ot Maintenance
The eqipment nder !reakdo%n maintenance is allo%ed to rn ntil it !reaks do%n and
then repairin' it and pttin' !ack to operation. This strate'$ is sita!le for eqipments
that are not critical and ha#e spare capacit$ or redndanc$ a#aila!le. In pre#enti#e or
schedled Maintenance, maintenance actions sch as inspection, l!rication, cleanin',
ad"stment and replacement are ndertaken at fi*ed inter#als of nm!ers of hors or
1ilometers. )n effecti#e PM pro'ram does help in a#oidance of accidents. Condition
monitorin' 2CM3 detects and dia'noses falts and it helps in planned maintenance !ased
on eqipment condition. This condition !ased maintenance strate'$ or predicti#e
maintenance is preferred for critical s$stems and for sch s$stems !reakdo%n
maintenance is to !e a#oided. ) nm!er of CM techniqes sch as #i!ration, temperatre,
oil anal$sis, etc. ha#e !een de#eloped, %hich 'ide the sers in planned maintenance ,4..
In opportnit$ maintenance, timin' of maintenance is determined !$ the procedre
adopted for some other item in the same nit or plant. In desi'n ot maintenance, the aim
is to minimi&e the effect of failres and in fact eliminates the case of maintenance.
)ltho'h it is an en'ineerin' desi'n pro!lem, $et it is often a responsi!ilit$ of
maintenance department. This is opted for items of hi'h maintenance cost that are de to
poor maintenance, poor desi'n or poor desi'n otside desi'n specifications. It ma$ !e
mentioned that a !est maintenance strate'$ for each item shold !e selected !$
considerin' its maintenance characteristics, cost and safet$.

In addition to the a!o#e, ne% strate'ies concepts sch as Proacti#e Maintenance,
5elia!ilit$ Centred Maintenance 25CM3, Total Prodcti#e Maintenance 2TPM3, etc. ha#e
recentl$ !een e#ol#ed to look it from different perspecti#es and this has helped in
de#elopin' effecti#e maintenance. In proacti#e maintenance, the aim is identif$ %hat can
'o %ron', i.e. !$ monitorin' of parameters that can case failres. In 5CM, the t$pe of
maintenance is chosen %ith relia!ilit$ of the s$stem in consideration, i.e. s$stem
fnctions, failres relatin' to those fnctions and effects of the dominant fnctional
s$stem failres. This strate'$ in the !e'innin' %as applied to critical s$stems sch as
aircrafts, nclear and space applications. )t present, this is !ein' e*tended to critical
s$stems in the plant. TPM, a 6apanese concept, in#ol#es total participation of all
concerned. The aim is to ha#e o#erall effecti#eness of the eqipment %ith participation of
all concerned sin' prodcti#e maintenance s$stem.
FUNTIONS OF A MAINTENANCE DEPARTMENT
+ollo%in' are the ma"or fnctions of a maintenance department ,789.:
Maintenance of installed eqipment and facilities
Installations of ne% eqipment and facilities
PM tasks ; Inspection and l!rication of e*istin' eqipment
CM tasks ; monitorin' of falts and failres sin' appropriate techniqes
Modifications of alread$ installed eqipment and facilities
Mana'ement of in#entor$
(per#ision of manpo%er
1eepin' records
MAINTENANCE ORGANIZATION
It concerns in achie#in' an optimm !alance !et%een plant a#aila!ilit$ and maintenance
resorce tili&ation. The t%o or'ani&ation strctres that are common are: Centrali&ed
and Decentrali&ed. ) decentrali&ed strctre %old pro!a!l$ e*perience a lo%er
tili&ation than centrali&ed one !t %old !e a!le to respond qickl$ to !reakdo%ns and
%old achie#e hi'her plant a#aila!ilit$. In practice, one ma$ ha#e a mi* of these t%o. )
maintenance or'ani&ation can !e considered as !ein' made p three necessar$ and
interdependent components.
-. Resources: men, spares and tools
4. Administration: a hierarch$ of athorit$ and responsi!ilit$ for decidin' %hat,
%hen and ho% %ork shold !e carried ot.
7. Work Pannin! and Contro S"stem: a mechanism for plannin' and schedlin'
the %ork and feedin' !ack the information that is needed for correctl$ directin'
the maintenance effort to%ards defined o!"ecti#e.
It ma$ !e mentioned that maintenance < prodction s$stem is a continosl$ e#ol#in'
or'anism in %hich the maintenance or'ani&ation %ill need continos modifications in
response to chan'in' reqirements. Moreo#er, it is reqired to match the resorces to
%orkload. Maintenance acti#ities ; !e it pre#enti#e or condition monitorin', in#ol#e se
of resorces8 men and materials incldin' docments. This reqires coordination
amon'st the in#ol#ed personnel so that these are timel$ ndertaken. =ork plannin' and
control s$stem nder maintenance mana'ement in the plant ensres this and pro#ides
plannin' and control of acti#ities associated %ith maintenance. This means application of
'eneral mana'ement principles of plannin', or'ani&in', directin' and controllin' to the
maintenance fnctions, e.'. to the esta!lishment of procedres for de#elopment of
maintenance strate'$ and to models for descri!in' the flo% of %ork thro'h maintenance
%ork plannin' department. Control s$stem controls the maintenance cost and plant
condition.
E#EMENTS OF EFFECTI$E MAINTENANCE MANAGEMENT
)n effecti#e maintenance s$stem incldes the follo%in' elements ,789.:
Maintenance Polic$
Control of materials
Pre#enti#e Maintenance
Condition Monitorin'
=ork Order
6o! plannin'
Priorit$ and !acklo' control
Data recordin' s$stem
Performance measrement measres or indices
Maintenance performance for a plant or an or'ani&ation can !e assessed thro'h anal$sis
of 5elia!ilit$, )#aila!ilit$ and Maintaina!ilit$ 25)M3 plant data. 5ele#ant parameters,
measres or indices for specific plants can !e identified ,>.. The performance o#er a
period of time %ill sho% if it is impro#in', 'oin' do%n or !ein' sstained. This %ill also
help in kno%in' ho% %ell the o!"ecti#es are !ein' met. In addition, it %ill 'ide the areas
%hich are stron' and %hich need to !e stren'thened. 0se of compters and dedicated
soft%are %ill certainl$ help in implementin' this and the maintenance mana'ement
s$stem in 'eneral.
CONC#USION
The a!o#e lectre has !riefl$ focsed on the #arios aspects of maintenance
mana'ement. Maintenance is e*pected to pla$ e#en mch !i''er role in $ears to follo%,
as indstries %orld%ide are 'oin' thro'h an increasin' and stiff competition and
increased atomation of plants. The do%n time cost for sch s$stems is e*pected to !e
#er$ hi'h. To meet these challen'es, maintenance has to se latest technolo'$ and
mana'ement skills in all spheres of acti#ities to perform its effecti#e role in profita!ilit$
of the compan$.
REFERENCES:
-. 1ell$, )nthon$, ?Mana'in' maintenance resorces@, /tter%orth8Aeinemann,
4BBC.
4. Collacott, 5.)., ?Mechanical falt dia'nosis@, Chapman and Aall, -DEE.
7. Fe#itt 6oel, ?Aand!ook of maintenance mana'ement@, Indstrial Press, -DDE.
9. =ilson )lan, ?)sset maintenance mana'ement@, Indstrial Press, 4BB4.
>. Ter$ =ireman, ?De#elopin' performance indicators for maintenance@, Indstrial
Press, 4BB>.