MAINTENANCE

ENGINEERING &
INDUSTRIAL
MANAGEMENT
CH371 Lecture
 BOOKS TO BE FOLLOWED
TEXT BOOK:

Maintenance Engineering Handbook By: R. Keith Mobley 7th Edition.

REFERENCE BOOKS:
• Maintenance Manager’s Standard Manual by Thomas A. Wester-kamp, Prentice-Hall.
• A Guide to Effective Industrial Safety by Jack W. Boley, Gulf Publishing Company.
• Harold Kerzner, “Project Management: A Systems Approach to Planning,
Scheduling, and Controlling”, Ninth Edition, John Wiley & Sons, 2006.
• Jay Heizer and Barry Render, “Principles of Operations Management”, 3rd Edition,
Prentice Hall, 1999.
• Jay Heizer and Barry Render, “Operations Management”, 5th Edition, Prentice Hall,
2000.
• Industrial Management Methods Ronald Hurst.
• Industrial Organization & Management BETHEL.

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 COURSE CONTENTS
 Maintenance, Preventive, predictive breakdown and total productive
maintenance, Individual versus group replacement, internal versus external
maintenance, scheduling of maintenance, computerized maintenance,
organization of maintenance force. Design constructions, layout and
constructions, maintenance of rotary and stationery equipment, inspection
techniques. Non destructive testing techniques, basics of rigging and lifting,
lubrication and lubricants.

 Industrial management, process layout analysis and comparison, material

handling consideration in layout, production planning methods, material
requirement planning, material resource planning, capacity planning and
control, production control systems, job shop scheduling, quality control,
production control charts, scheduling techniques, software for project
management, purchasing and procurement, inventory control, time & motion
study, EOQ/EPQ models, organizational structure, HRM, project management
principles, PERT/CPM, total quality management, ISO standards, Labour and 3
engineering laws, labour problems, labour organizations, prevention and
settlement of disputes.
INTRODUCTION TO
MAINTENANCE
Scope & Types
EFFECTS OF MAINTENANCE

• Reliability
• Product Quality
• Productivity
• Safety
• Supply Chain

Failure cause disruption, waste, accident,

inconvenience and expense. 5
• Operators less able to do repairs
themselves
• Machine and product failure can have
effect on company’s operation and
profitability
• Idle workers, facility
• Losses due to breakdown
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FAILURE

• Failure – inability to produce work in appropriate

manner
• Equipment / machine failure on production floor
– worn out bearing, pump, pressure leaks, broken
shaft, overheated machine etc.
• Equipment failure in office – failure of power
supply, air-conditioned system, computer
network, photocopy machine
• Vehicle failure – brake, transmission, engine,
cooling system
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 MAINTENANCE IN SERVICE
INDUSTRY
• Hospital
• Restaurants
• Transport companies
• Banks
• Hotels and resorts
• Shopping malls / retail
• Gas station
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MAINTENANCE IN MANUFACTURING
INDUSTRY
• Electronic
• Automotive
• Petrochemicals
• Refinery
• Chemicals
• Ceramics
• Food and beverages
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 MAINTENANCE
All actions necessary for retaining an item, or
restoring to it, a serviceable condition, include
servicing, repair, modification, overhaul,
inspection and condition verification.

Increases availability of a system

Keep system’s equipment in working order

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QUESTION!
• Why do we need maintenance?
• What are the costs of doing maintenance?
• What are the costs of not doing
maintenance?
• What are the benefits of maintenance?
• How can maintenance increase profitability
of company?
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 PURPOSE OF MAINTENANCE

• Attempt to maximize performance of

production equipment efficiently and
regularly
• Prevent breakdown or failures
• Minimize production loss from failures
• Increase reliability of the operating
systems.
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 PRINCIPLE OBJECTIVES IN
MAINTENANCE
• To achieve product quality and customer
satisfaction through adjusted and serviced
equipment.
• Maximize useful life of equipment.
• Keep equipment safe and prevent safety hazards.
• Minimize frequency and severity of interruptions.
• Maximize production capacity – through high
utilization of facility.

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PROBLEMS IN MAINTENANCE

• Lack of management attention to maintenance.

• Little participation by accounting in analyzing and
reporting costs.
• Difficulties in applying quantitative analysis.
• Difficulties in obtaining time and cost estimates for
maintenance works.
• Difficulties in measuring performance.

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PROBLEMS EXIST DUE TO:
• Failure to develop written objectives and policy.
• Inadequate budgetary control.
• Inadequate control procedures for work order,
service requests etc.
• Infrequent use of standards to control
maintenance work.
• Absence of cost reports to aid maintenance
planning and control system.

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MAINTENANCE OBJECTIVES

• Must be consistent with the goals of

production (cost, quality, delivery, safety)

• Must be comprehensive and include

specific responsibilities

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MAINTENANCE COSTS

• Cost to replace or repair

• Losses of output

• Delayed shipment

• Scrap and rework

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TYPES OF MAINTENANCE
Despite developments in equipment and facilities,
maintenance needs remain the same. For this reason, and
understanding maintenance as a set of technical actions to
regulate the normal operation of these same pieces of
equipment, we can divide it into following major groups:
• Corrective or Breakdown maintenance

• Scheduled maintenance

• Preventive maintenance

• Predictive (Condition-based) maintenance 18

TYPES OF MAINTENANCE
Corrective or Breakdown Maintenance
Corrective or Breakdown maintenance implies that
corrections or repairs are made after the equipment is failed
and can not perform its normal function anymore.

• Quite justified in small factories where Down times are

non-critical and repair costs are less than other type of
maintenance.

• Equipment with weak designs are redesigned to improve

reliability or improving maintainability
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Advantages of Corrective Maintenance

• Lower short-term costs

• Minimal planning is required

• The process is very simple so it is easy to understand

• Fewer staff are required as less work is done day-to-day

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Limitations of Corrective Maintenance

• Unpredictability: Breakdown generally occurs inappropriate

times leading to poor and hurried maintenance

• Paused operations: Excessive delay in production & reduces

output in some cases

• Low plant/Equipment life

• The process poses a safety risk to employees and other assets.

• Higher long-term costs: When a more serious failure occurs, it can be 21

an extremely costly and slow process to fix.

TYPES OF MAINTENANCE
Scheduled Maintenance
Scheduled maintenance is a stitch-in-time procedure and
incorporates
 Inspection
 Lubrication
 Repair and overhaul of equipment
• doesn’t rely on the actual equipment’s state but rather on
the programs delivered by manufacturers.
• Generally followed for:
 Overhauling of machines 22
 Changing of heavy equipment oils
 Cleaning of water and other tanks etc.
 TYPES OF MAINTENANCE
Preventive Maintenance (PM)

• Principle – “Prevention is better than cure”

• Preventive maintenance arises as opposed to corrective

maintenance. Instead of waiting for the malfunction to occur,
this type of maintenance aims to prevent it from happening.

• Preventive maintenance occurs in a cyclical and programmed

manner, regardless of the condition of the asset and in order to
avoid malfunctions and minimize the consequences of
equipment failures. 23
 Preventive Maintenance (PM)

Advantages:
• Reduces break down and thereby down time

• Long-term repair costs are usually significantly lower

• Better product quality and Less stand-by equipment

• Safety is improved due to reduced likelihood of catastrophic

failure

Disadvantages:
• More complex than other types of maintenance
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• Requires more investment
TYPES OF MAINTENANCE
Predictive (Condition-based) Maintenance
• The goal of predictive maintenance is to predict when a
malfunction is about to occur. When certain undesirable
conditions are detected, then a repair is scheduled.

• It is based on the physical and operational condition of the

equipment, through regular monitoring and testing, using
advanced techniques such as vibration analysis, oil
analysis, acoustics, infrared tests, or thermal imaging.

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 Condition based Maintenance

Advantages:
• Problems with components can be identified prior to failure

• Repairs can be carried out on assets to keep them running with

minimal disruption to productivity

• Long-term costs are very low compared with the cost of failure

Disadvantages:
• Short-term investment is required in specific monitoring
equipment, as well as in training staff 26