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MAINTENANCE MANAGEMENT INTRODUCTION

The term maintenance means to keep the equipment in operational condition or repair it to its operational mode. Maintenance management involves managing the functions of maintenance. Main objective of the maintenance is to have increased availability of production systems, with increased safety and optimi ed cost. Therefore, maintenance Management is an orderly and systematic approach to planning, organi ing, monitoring and evaluating maintenance activities and their costs. ! good maintenance management system coupled with knowledgeable and capable maintenance staff can prevent health and safety problems and environmental damage" yield longer asset life with fewer breakdowns and result in lower operating costs and a higher quality of life. Maintaining equipment in the field has been a challenging task since the beginning. #ince then, a significant of progress has been made to maintain equipment effectively in the field. !s the engineering equipment becomes sophisticated and e$pensive to produce and maintain, maintenance management has to face even more challenging situations to maintain effectively such equipments in industrial environment. This brief lecture on maintenance management includes maintenance strategies, functions of maintenance department, maintenance organi ation and elements of maintenance management.

TYPES OF MAINTENANCE
The word %&peration' is usually linked with %Maintenance'. To put these terms in conte$t, &peration is the performance of work or services and the provision of materials and energy to ensure the day(to(day proper functioning of an asset, e.g., the work activities, associated chemicals and electricity to run a water treatment plant. !s such, it has a direct but simple impact on the cost of operating an asset. Maintenance is the work performed on an asset such as a road, building, utility or piece of equipment to preserve it in as near to its original condition as is practical and to reali e its normal life e$pectancy. This Technical )nformation *ocument, as its name implies, concentrates on maintenance management systems only. )n general, maintenance can be classified into the following categories+ a, -outine ( ongoing maintenance activities such as cleaning washrooms, grading roads and mowing lawns, which are required because of continuing use of the facilities" b, .reventive ( periodic adjustment, lubrication and inspection of mechanical or other equipment to ensure continuing working condition" c, major projects such as floor replacement, re(roofing, or complete re(painting which are performed once every few years" and d, /mergency ( une$pected breakdowns of assets or equipment. These are unpredictable or reactive type of maintenance and are more difficult to schedule than the above three categories.

MAINTENANCE STRATEGIES ! maintenance strategy means a scheme for maintenance which contains an elaborate and systematic plan of maintenance action. 0ollowing are the maintenance strategies that are commonly applied in the plants. 1reakdown Maintenance or &perate to 0ailure or 2nplanned Maintenance .reventive or #cheduled Maintenance .redictive or 3ondition 1ased Maintenance &pportunity Maintenance *esign out Maintenance

The equipment under breakdown maintenance is allowed to run until it breaks down and then repairing it and putting back to operation. The aim is to have overall effectiveness of the equipment with participation of all concerned using productive maintenance system. This strategy is suitable for equipments that are not critical and have spare capacity or redundancy available. )n preventive or scheduled Maintenance, maintenance actions such as inspection, lubrication, cleaning, adjustment and replacement are undertaken. This condition based maintenance strategy or predictive maintenance is preferred for critical systems and for such systems breakdown maintenance is to be avoided. )n opportunity maintenance, timing of maintenance is determined by the procedure adopted for some other item in the same unit or plant. )n design out maintenance, the aim is to minimi e the effect of failures and in fact eliminates the cause of maintenance. )t may be mentioned that a best maintenance strategy for each item should be selected by considering its maintenance characteristics, cost and safety. )n addition to the above, new strategies concepts such as .roactive Maintenance, -eliability 3entred Maintenance 4-3M,, and Total .roductive Maintenance 4T.M, have recently been evolved to look it from different perspectives and this has helped in developing effective maintenance.

FUNTIONS OF A MAINTENANCE DEPARTMENT 0ollowing are the major functions of a maintenance department+ Maintenance of installed equipment and facilities )nstallations of new equipment and facilities .M tasks 5 )nspection and lubrication of e$isting equipment 3M tasks 5 monitoring of faults and failures using appropriate techniques Modifications of already installed equipment and facilities Management of inventory #upervision of manpower 6eeping records

MAINTENANCE ORGANIZATION )t concerns in achieving an optimum balance between plant availability and maintenance resource utili ation. The two organi ation structures that are common are+ 3entrali ed and *ecentrali ed. ! decentrali ed structure would probably e$perience a lower utili ation than centrali ed one but would be able to respond quickly to breakdowns and would achieve higher plant availability. )n practice, one may have a mi$ of these two. ! maintenance organi ation can be considered as being made up three necessary and interdependent components. 7. Resources+ men, spares and tools 8. Administration+ a hierarchy of authority and responsibility for deciding what, when and how work should be carried out. 9. Wor P!annin" and Contro! S#stem + a mechanism for planning and scheduling the work and feeding back the information that is needed for correctly directing the maintenance effort towards defined objective. Maintenance production system is a continuously evolving organism in which the maintenance organi ation that need continuous modifications in response to changing requirements. :owever, it is required to match the resources to workload. Maintenance activities will be it preventive or condition monitoring, involve use of resources, men and materials including documents. This requires coordination amongst the involved personnel so work planning and control system under maintenance management in the plant will run smoothly and provides planning and control of activities associated with maintenance. 3ontrol system controls the maintenance cost and plant condition.

E$EMENTS OF EFFECTI%E MAINTENANCE MANAGEMENT !n effective maintenance system includes the following elements+ Maintenance .olicy 3ontrol of materials .reventive Maintenance 3ondition Monitoring ;ork &rder <ob planning .riority and backlog control *ata recording system .erformance measurement measures or indices

Maintenance performance for a plant or an organi ation can be assessed through analysis of -eliability, !vailability and Maintainability 4-!M, plant data. -elevant parameters, measures or indices for specific plants can be identified. The performance over a period of time will show if it is improving, going down or being sustained will show since the application of the management on maintenance have been undertaken. 2se of computers and dedicated software will certainly help in implementing this and the maintenance management system in general. #o then the =overnment have implement 3omputeri ed Maintenance Management #ystem 43MM#, to almost the government building which will be monitored by <abatan 6erja -aya 4<6-,.

CONC$USION The above lecture has briefly focused on the various aspects of maintenance management. Maintenance is e$pected to play even much bigger role in years to follow, as industries worldwide are going through an increasing and stiff competition and increased automation of plants. The down time cost for such systems is e$pected to be very high. To meet these challenges, maintenance has to use latest technology and management skills in all spheres of activities to perform its effective role in profitability of the company.

REFERENCES+ 7. 6elly, !nthony, %Managing maintenance resources', 1utterworth(:einemann, 8>>?. 8. 3ollacott, -.!., %Mechanical fault diagnosis', 3hapman and :all, 7@AA. 9. Bevitt <oel, %:andbook of maintenance management', )ndustrial .ress, 7@@A. C. ;ilson !lan, %!sset maintenance management', )ndustrial .ress, 8>>8. D. Tery ;ireman, %*eveloping performance indicators for maintenance', )ndustrial .ress, 8>>D.