Professional Documents
Culture Documents
ENGINEERING
• SAFETY
Note: Some data/images in this presentation is takes from different books and internet and is
only used for educational purposes. Credit goes to original authors only.
MAINTENANCE ENGINEERING
MAINTENANCE
The act of maintaining or the state of being maintained.
The work of keeping something in proper condition; upkeep.
care or upkeep, as of machinery or property: With proper mai
ntenance the car WILL last for many years.
Any activity – such as tests, measurements, replacements,
adjustments and repairs — intended to retain or restore
a functional unit in or to a specified state in which the unit
can perform its required functions.
For material — all action taken to retain material in a
serviceable condition or to restore it to serviceability. It
includes inspection, testing, servicing, classification as to
serviceability, repair, rebuilding, and reclamation.
MAINTENANCE ENGINEERING (Cont.)
PLANT
Preventive maintenance
Corrective or Breakdown maintenance
Scheduled maintenance
Predictive (Condition-based) maintenance
PLANNED UNPLANNED
MAINTENANC MAINTENANC
E (PROACTIVE) E (REACTIVE)
EMERGENCY BREAKDOWN
Shutdown Maintenance
Cost
Breakdown Cost
Maintenance
Commitment
MAINTENANCE COSTS
Cost
PM Cost
Breakdown Cost
Maintenance
Commitment
MAINTENANCE COSTS
Cost
Total Maintenance Cost
PM Cost
Breakdown Cost
Maintenance
Commitment
MAINTENANCE COSTS
Cost
Total Maintenance Cost
PM Cost
Breakdown Cost
Optimal Maintenance
Commitment
OPERATIONAL MAINTENANCE
Where equipment is maintained in OPERATING CONDITION.
1.Eliminating breakdown
2.Eliminating deviation
managing.
RELIABILITY CENTERED
MAINTENANCE (Cont.)
It regards maintenance as the means to maintain the
functions a user may require of machinery in a defined
operating context. As a discipline it enables machinery
stakeholders to monitor, assess, predict and generally
understand the working of their physical assets. This is
embodied in the initial part of the RCM process which
is to identify the operating context of the machinery,
and write a Failure Mode Effects and Criticality Analysis
(FMECA). The second part of the analysis is to apply the
"RCM logic", which helps determine the appropriate
maintenance tasks for the identified failure modes in the
FMECA.
DETERMINING THE SIZE OF
REPAIR CREWS
Problem:
A factory has 200 machines and the
maintenance engineer supervises the repair
crews who repair malfunctioning machines.
The maintenance policy is to repair the
broken down machine and bring back in
production within 2 hours on the average. If
average breakdown rate is 3.5
machines/hour and each repair crew can
repair 0.25 machine per hour on the
average. How many repair crews are
required ?
SOLUTION
The formula for average repair rate () is
1
ts = ---------- or = + 1/ ts
-
Where = repair rate
= arrival rate of malfunctioning machines
ts = average time arrivals in the system