Subject: Production and Operations Management

Unit 5: Maintenance and Waste Management

B Y:
M A S I A B H A N U. U
A S S I S TA N T P R O F E S S O R
CITY COLLEGE
Meaning of Maintenance:

 Maintenance is ―that function of manufacturing management that is concerned with day-to-day problem of keeping the
physical plant in good operating condition.
 It is an essential activity in every manufacturing establishment, because it is necessary to insure the availability of the
machines, buildings and services needed by other parts of the organization for the performance of their function at an
optimum return on their investment, whether this investment is in machinery materials or employees‖.

Definition of Maintenance Management:

MAINTENANCE MANAGEMENT- Concerned with planning, organizing and directing the resources in order to control the
availability and performance of the industrial plants to some specified level.
The main objectives of maintenance management are as follows:

(1) Minimizing the loss of productive time because of equipment failure to maximize the availability of plant,
equipment and machinery for productive utilization through planned maintenance.

(2) To extend the useful life of the plant, machinery and other facilities by minimizing their wear and tear.

(3) Minimizing the loss due to production stoppages.

(4) To ensure operational readiness of all equipment’s needed for emergency purposes at all times such as fire-
fighting equipment.

(5) Efficient use of maintenance equipment’s and personnel.

(6) To ensure safety of personnel through regular inspection and maintenance of facilities such as boilers,
compressors and material handling equipment etc.

(7) To maximize efficiency and economy in production through optimum utilization of available facilities.

(8) To improve the quality of products and to improve the productivity of the plant.

(9) To minimize the total maintenance cost which may consist of cost of repairs, cost of preventive maintenance
and inventory costs associated with spare parts/materials required for maintenance.

(10) To improve reliability, availability and maintainability

Importance of Maintenance Management
 Maintenance management is responsible for the smooth and efficient working of the industrial plant and helps
in improving the productivity.

 It also helps to keep the machines/equipment in their optimum operating conditions. Thus plant maintenance
is an important and inevitable service function of an efficient production system.

 It also helps in maintaining and improving the operational efficiency of the plant facilities and hence
contributes towards revenue by decreasing the operating cost and improving the quality and quantity of the
product being manufactured.

 As a service function it is related with the incurrence of certain costs. The important component of such costs
are — employment of maintenance staff, other minor administrative expenses, investment in maintenance
equipment and inventory of repair components/ parts and maintenance materials.
Types of Maintenance

1) Corrective maintenance: Corrective maintenance occurs when there is a work stoppage because of machine
breakdown. Maintenance becomes repair work and is performed to restore the equipment back to its acceptable
performance. Breakdown maintenance is also called operate-to-failure maintenance, fire-fighting-maintenance or
unplanned maintenance.

2) Predictive maintenance: one of the newer types of maintenance that maybe anticipated to gain increasing
attention is called predictive maintenance. It is a preventive type of maintenance that involves the use of sensitive
instruments to predict trouble. Condition can be measured periodically or on a continuous basis and this enables
the maintenance people to plan for overhaul.

3) Preventive maintenance: it is taken before the need arises and aims to minimize the possibility of unanticipated
production interruption or major breakdowns. It consists of :
a)proper design and installation of equipment,
b)periodic inspection of plant and equipment to prevent breakdowns before they occur,
c)repetitive servicing, upkeep and overhaul of equipment
d)adequate lubrication, cleaning and painting of buildings and equipment.
Elements of Effective Maintenance Management:
• Maintenance Policy
• Control of materials
• Preventive maintenance
• Condition Monitoring
• Work Order
• Job planning
• Priority and backlog control
• Data recording system
• Performance measurement measures
MODERN SCIENTIFIC MAINTENANCE METHODS

1) Reliability-centered maintenance (RCM) is a concept of maintenance planning to ensure that systems continue to do
what their user require in their present operating context.[1] Successful implementation of RCM will lead to increase in
cost effectiveness, reliability, machine uptime, and a greater understanding of the level of risk that the organization is
managing.
Reliability centred maintenance (RCM) is a corporate-level maintenance strategy that is implemented to optimize
the maintenance program of a company or facility. The final result of an RCM program is the implementation of a
specific maintenance strategy on each of the assets of the facility.
2)SIX SIGMA MAINTENANCE :
Six Sigma is a maintenance process that focuses on
reducing the variation in production processes. By reducing variation, a business can achieve tither control over
its operational systems, increasing their cost effectiveness and encouraging productivity breakthrough.

The main methodologies of Six Sigma are Define, Measure, Analyze, Improve, Control (DMAIC) and Design
for Six Sigma (DFSS). This article will deal with DMAIC applied to existing processes, as opposed to DFSS,
which is used in the implementation of new products or services. It is important to use creativity to mold
expectations about Six Sigma. The methodology is flexible and will not replace or diminish any technique or tool
already used, but will add to them. This fear is common and must be prevented to avoid resistance that will
destroy the program.
3)Enterprise asset management (EAM) is the process of managing the lifecycle of physical assets to maximize their use; save
money; improve quality and efficiency; and safeguard health, safety and the environment.
Enterprise asset management involves the management of the maintenance of physical assets of an organization throughout
each asset's lifecycle. EAM is used to plan, optimize, execute, and track the needed maintenance activities with the
associated priorities, skills, materials, tools, and information.

4)Lean maintenance: is a proactive maintenance operation employing planned and scheduled maintenance activities
through total productive maintenance (TPM) practices using maintenance strategies developed through application of
reliability centered maintenance (RCM).
Lean Maintenance is a key ingredient to a successful Lean Manufacturing environment.
Lean Manufacturing seeks to cut out three types of waste:
 Processes that do not add value for the customer
 Inefficiencies in processes
 Variations in the pace of production.
Lean Maintenance supports a Lean Manufacturing approach by preventing unscheduled downtime. The method is to reduce
or eliminate the factors that cause machine breakdowns.
5) Computer-aided maintenance: refers to systems that utilize software to organize planning, scheduling and
support of maintenance and repair. A common application of such systems is the maintenance of computers, either
hardware or software, themselves. It can also apply to the maintenance of other complex systems that require
periodic maintenance, such as reminding operators that preventive maintenance is due or even predicting when
such maintenance should be performed based on recorded past experience.
Maintenance Schedule

Meaning: Maintenance Schedule is a list of planned Maintenance tasks to be performed during a given time
period, together with the expected start times and durations of each of these tasks. Schedules can apply to different
time periods i.e. daily schedule, weekly schedule etc.,

A Maintenance Scheduler is responsible to take a maintenance plan and bring together all the resources needed
to complete it. The Scheduling role involves assembling and coordinating the information, people, materials,
equipment, along with all the other necessary resources to get the job done.
SPARES PLANNING AND CONTROL
 A spare part, spare, service part, repair part, or replacement part, is an interchangeable part that is kept in an
inventory and used for the repair or replacement of failed units. Spare parts are an important feature of logistics
engineering and supply chain management, often comprising dedicated spare parts management systems.

 A spares management process is a system between a company and a spare parts supplier to provide a
direct way to inventory and ship spares before you need them.

Benefits of spare parts management:

1. Allows you to keep spare inventory levels low, reducing carrying and storage costs but providing access to spare parts
when needed.
2. Better service to your customers. The longer your operations are up and running, the better you’re able to deliver
the services and support your customers demand.
3. Enhanced part visibility so your supply chain can show where the need is and where the parts are headed.
4. Improved equipment uptime as you limit how long equipment is down and don’t have to wait to generate revenue
or find a funding source to repair a part when it breaks.
5. Quicker repairs and replacements for defective parts, plus assistance with larger failures.
WASTE MANAGEMENT

MEANING OF WASTE: Waste is that portion of raw material lost in processing, having no recovery value. Waste can be
visible or invisible and has no value. Visible waste is physically present say saw dust, ash etc. Invisible waste is the
disappearance of basic raw materials in form of evaporation, smoke, loss in weight due to chemical reaction, and so on.
Waste may be solid or liquid.

TYPES OF WASTE: The different forms of waste are:

1) Scrap: Scrap is the discarded material from a manufacturing
job.
Eg: If an automaker is manufacturing a car and has steel
leftover after finishing the car, that leftover steel is considered
scrap. It’s excess material that’s not required to manufacture
the car. However, scrap can also be a complete batch of parts
that needs to be recycled.
2)Surplus: is when a company has more resources or assets than it can use in production. In other words, it's
when a business' assets exceed the useful demand for them. This concept often refers to excess production
capacity, but it is also used in the budgeting process when income exceeds expenses.

3) Spoilage: is wastage or loss of material that occurs during the manufacturing process, it can also be used
to classify badly damaged material that is used for processing a product. Spoilage is used to refer most
commonly to raw materials whose lifespan is very short.

4)Defectives: Defective work is that portion of production which is below standard specification or quality and
cab be rectified by incurring additional expenditure on material, labour and works overheads known as
“rectification cost”.

5) Salvaged Items: Are those items which cannot be put to use for their original purpose for which they were
procured.
Sources of Waste:

1. Obsolete Items: Outdated items.

2. Surplus
3. Scrap

MEANING OF WASTE MANAGEMENT:

Waste management is the collection, transport, processing or disposal monitoring of waste materials. It is the control and
reduction of material losses that occur during handling ,storage and process of manufacture.

Methods of Disposal of Waste:

1) Landfill: A landfill is a site for the disposal of waste materials by
burial. Landfill is the oldest form of waste treatment, although the
burial of the waste is modern; Landfills were often established in
abandoned or unused quarries, mining voids or borrow pits. Historically,
landfills have been the most common method of organized waste
disposal and remain so in many places around the world.
2) Incineration: Incineration is a disposal method in which solid organic wastes are subjected to combustion(the process of
burning something.) so as to convert them into residue and gaseous products. This method is useful for disposal of both
municipal solid waste and solid residue from waste water treatment. Incineration and other high temperature waste treatment
systems are sometimes described as "thermal treatment". Incinerators convert waste materials into heat, gas, steam,
and ash.

Automatic Paper Waste Incinerator Incinerator Hospital Waste

3)Recycling: Recycling is a resource recovery practice that refers to the collection and reuse of waste
materials such as empty beverage containers. The materials from which the items are made can be
reprocessed into new products. Material for recycling may be collected separately from general waste
using dedicated bins and collection vehicles, a procedure called kerbside collection.

4) Sustainability: The management of waste is a key component in a business' ability to

maintain ISO14001 accreditation. The standard encourages companies to improve their environmental efficiencies
each year by eliminating waste through resource recovery practices. One way to do this is by adopting resource
recovery practices like recycling materials such as glass, food scraps, paper and cardboard, plastic bottles and metal.
Recycled materials can often be sold to the construction industry.

5) Biological reprocessing: Recoverable materials that are organic in nature, such as plant material, food scraps, and
paper products, can be recovered through composting and digestion processes to decompose the organic matter.
The resulting organic material is then recycled as mulch or compost for agricultural or landscaping purposes.
6) Resource recovery: Resource recovery is the systematic diversion of waste, which was intended for
disposal, for a specific next use. It is the processing of recyclables to extract or recover materials and
resources, or convert to energy. These activities are performed at a resource recovery facility. Resource
recovery is not only environmentally important, but it is also cost-effective. It decreases the amount of waste
for disposal, saves space in landfills, and conserves natural resources.