Maintenance

Management Assignment

Submitted by
Rohit Raj
BFT/20/90
Objectives of Maintenance Department

There are various objectives of the maintenance
department. It basically deals with the maximization of
facilities/ equipment availability to achieve a certain goal
for an organization. But at the same time, it also deals
with safety-related issues ensuring safe working
conditions for the operator/ worker and the maintenance
personnel. Fig 1. below highlights the fundamental
objectives of the Maintenance Department in brief.
The department is also responsible for foreseeing the
wear and tear of any equipment (especially the critical
ones). All of these help to eliminate future defects and
prevent any kind of machine breakdowns during
operation.
Cost-
On-time maintenance of the machine reduce the cost as

Elimination of Prevent breakdown

fututre defects during operation

Foresee rapid Ensure Safety

wear of components Productivity Improvement
through maximum
availability at optimum cost
Enhance Maximise
Performance Level Efficiency

Reduce Reduce
Maintenance Cost Idle hours

Fig. 1 Objectives of Maintenance

Optimum Working conditions -
Maintenance focuses on optimum working conditions for
equipment with minimum operating cost. It also creates a
healthy working environment for the operator.
On-time Delivery -
It ensures that the delivery time is never affected and all
the machines/equipment involved in the production run
smoothly.
it prevents any major breakdowns. And since it is also
maximizing efficiency, so accordingly the profits
increase.
Maintenance Department in Appare Industry
The objectives of the maintenance department in the
Garment Industry remain the same as before. But just to
generalize, the objectives are as follows -

Performance - Reduced machine breakdown,

The downtime of the machine is as minimum as possible. Lower maintenance cost
The performance of the machine is made sure that it is Lower product cost
reliable. Improved Machine Performance

Breakdowns - A factory can gain substantial benefit by setting up

Since the maintenance department is responsible for defined work responsibilities and making a list of
ensuring the performance of the machines, so it also activities to be done by the maintenance department other
ensures that the downtime of the machine is minimum than just repairing machines when it breakdowns.
 Types of Maintenance

Maintenance

Breakdown Planned Corrective Preventive Predictive

CBM RCM CMMS TPM
Maintenance Maintenance Maintenance Maintenance Maintenance

Breakdown Maintenance Planned Maintenance

Breakdown Management means no work or maintenance
is done until the equipment fails or becomes inoperative.
No advance steps are taken to prevent the machine from
breakdown.
Although the lubrication and minor adjustments are done
from time to time no major maintenance is done.
Planned maintenance refers to any strategy where you
plan and perform maintenance tasks before a fault occurs.
It is quite similar to preventive maintenance as it is also
done in advance.
Planned Maintenance can be done in the following steps -

During the repair time, no proper care is taken to know
the real cause of the breakdown, which may lead to
similar frequent failures.
Breakdown Management may look less expensive but in
reality, it isn't because of frequent machine breakdowns
and in the industry with large number of machines.
Identify a problem and create a work order
Assess the worksite and the asset
Detail the process and order the necessary parts
Assign a work order priority
Schedule and Complete the maintenance

Breakdown

Computer

Decison
What to do?

YES NO
Request for Check for Excecution:
help help Breakdwon Repair

Help & Facilities Repair Work

Arranged Order and Materials
Check, inform Information to
Maintenance Incharge Production

Fig. 2 Breakdown Maintenance Flow Diagram

Corrective Maintenance

Corrective Maintenance means maintenance actions for Importance of Preventive Maintenance

correcting/ restoring a failed unit. It may include various
types of actions and minor adjustments. The fact to be
noted is that it can be both planned and unplanned.
When it comes to priority management, preference is
first given to critical machines/equipment and then the
lower ones.
It can be done in the following stages/ steps -
A preventive maintenance schedule helps you organize
and prioritize your maintenance tasks so that a
maintenance technician is able to create the best working
condition and life span for the equipment.
By conducting regular preventive maintenance, you can
ensure your equipment continues to operate efficiently
and safely.

Analysis
Identifying the Causes
Predictive Maintenance
Finding out the best possible solutions
Implementation
Regular Evaluation of the actual operating
conditions of Plant Equipment and production
Preventive Maintenance
systems.
It is the utilization of planned and coordinated
inspections, adjustments, repairs, and replacements in
maintaining plant

Fig. 3 Stages of Preventive Management

It is designed for day-to-day maintenance like cleaning,
inspection, lubrication, and retightening to retain the
healthy condition of the equipment
Plan and schedule the maintenance work w/o interruption
in production schedule improves availability
Provides timely factual data that states the operating
conditions of critical production systems and the
effectiveness of critical plant functions such as
purchasing, Engineering, and Production
Routine Maintenance

It is the simplest form of planned maintenance. It means
carrying out minor maintenance jobs at regular intervals.
The jobs may vary as cleaning, lubrication, inspection,
pressure flow, etc.
The frequency of routine-based maintenance is generally
once every shift. But depending upon the criticality of the
work/ machine, the frequency may increase.
Routine Maintenance is very important for effective and
efficient working of an industry.
Compared with preventive maintenance, this increases
the time between maintenance repairs, because
maintenance is done on an as-needed basis.
For condition-based maintenance to be successful, there
are several other elements of your maintenance operation
that need to be in place.
That includes having a scheduled maintenance strategy
that allows you to inspect and spot anomalies in
equipment, and trigger timely follow-up work orders as
well.

This can be further taken to the next level by integrating

it to AI.
Data

Inform Operation
Routine & concerned
Scheduling maintenance men Excution
Work Order

Inform Operation
& concerned
Feedback agencies Check

Fig. 4 Flow Diagram for Routine Maintenance

Condition-Based Maintenance Reliability Centered Maintenance

CBM, also known as Condition-based Management, is
carried out in response to a significant deterioration in a
unit or system as indicated by a change in a monitored
parameter
It is most suited for high capital cost equipment and
complex replaceable items
RCM is basically used to identify the maintenance
requirements of equipment
It establishes Functional Requirements and the desired
performance standards of the equipment and then relates
to design and inherent reliability parameters of the
machine.
RCM focuses on how the equipment performs and its
ability to meet company needs within the parameters of
environmental safety and government standards.
Here, it is important to kno the scope of the functions as
well as their limitations and methods of use relating to
safety and environmental measures.
Computerized Maintenance Management
System
A computerized maintenance management system will
contain a number of integrated programs or modules to
improve the efficiency and effectiveness of maintenance
functions. It is a type of preventive maintenance.
The core of a CMMS is its database. It has a data model
that organizes information about the assets a maintenance
organization is charged with maintaining, as well as the
equipment, materials, and other resources to do so.
Some of the functions of CMMS may include -
Tracking Work Order
Recording Asset History
Managing Inventory
Scheduling Tasks
The deployment of maintenance management software
starts with the equipment management module. It
consists of an asset directory that allows one to list and
describe all the industry assets.
This system makes it possible to link each piece of
equipment to a site or to another machine, which
facilitates the maintenance management of complex
systems.
Total Productive Maintenance
TPM (Total Productive Maintenance) is a
holistic approach to equipment maintenance
that strives to achieve perfect production
it focuses on -
No Breakdowns
No Small Stops or Slow Running
No Defects
In addition, it values a safe working environment.
TPM emphasizes proactive and preventative maintenance
to maximize the operational efficiency of the equipment.
It blurs the distinction between the roles of production
and maintenance by placing a strong emphasis on
empowering operators to help maintain their equipment.
The implementation of a TPM program creates a shared
responsibility for equipment that encourages greater
involvement by plant floor workers. In the right
environment, this can be very effective in improving
productivity (increasing up time, reducing cycle times,
and eliminating defects).
There are various pillars of TPM. They are as follows -
Autonomous Maintenance
Planned Maintenance
Integrated Quality
Improvement
Safety
Early Equipment Management
Advantages of TPM may include -
Fewer Breakdowns - When the breakdowns of the
machines are spotted in advance, it reduces the chances
of major machine breakdown
Safer Workplace - Technicians are much more likely to
take risks when rushing to fix a breakdown, so fewer
breakdowns generally mean a safer workplace.
Better Overall Performance - It takes the pressure of
small jobs off the maintenance team so they can
concentrate on the bigger jobs, which increases the
overall performance of your facility.
Latest Trends in Maintenance Management
Augmented Reality
Augmented Reality is the latest trend in the field of
maintenance management. The possibilities and
applications of augmented reality are endless, and it is
making its way into different industries, such as
manufacturing, construction, and so on. Users can stand
in front of the machines and view the operating
instructions. Furthermore, maintenance technicians can
use a digital checklist to perform equipment
maintenance.
One of the major disadvantages of AR is that it is
expensive.
Virtual technology and the Internet of
Things
Internet of Things is poised to fast-track its way into a
more commonplace method of carrying out maintenance
diagnostics and troubleshooting. Sensors and other
technology can provide a near “hands-on” experience for
offsite personnel, enabling accurate, real-time
maintenance processes from anywhere.
The industrial internet of things (IIoT), and data-driven
processes comprise the basis of almost every major 2022
trend. As a technology-driven leader in outsourced
industrial maintenance.
Advanced Sensors
With the advent of smart machinery, many facilities are
gradually becoming exposed to the benefits of equipment
sensors. These track performance and provide insight
into red flags such as abnormal vibration, heat or noise,
all of which can foretell an eventual machine breakdown.
This enables the issue to be addressed before it creates a
service disruption.
Computerized Maintenance Management
System
A computerized maintenance management system will
contain a number of integrated programs or modules to
It improves the efficiency and effectiveness of
maintenance functions. It is a type of preventive
maintenance. The core of a CMMS is its database. It has
a data model that organizes information about the assets
a maintenance organization is charged with maintaining,
as well as the equipment, materials, and other resources
to do so.
Some of the functions of CMMS may include -
Tracking Work Order
Recording Asset History
Managing Inventory
Scheduling Tasks
The deployment of maintenance management software
starts with the equipment management module. It
consists of an asset directory that allows one to list and
describe all the industry assets.
This system makes it possible to link each piece of
equipment to a site or to another machine, which
facilitates the maintenance management of complex
systems.
Additive Manufacturing
There are numerous cases where an equipment
malfunction will occur unless a component is replaced.
In such cases, additive manufacturing can rapidly
produce the needed part. This expedites maintenance
times and reduces inventory costs.
3D printing is also an obvious solution when parts that
are discontinued (i.e. no longer produced and/or provided
by the equipment manufacturer) are needed.
Printing a discontinued part increases a machine’s
longevity while removing the need for a costly
replacement due to the lack of a certain part. Despite the
fact that a complete replacement cannot be avoided for a
long time, additive manufacturing provides a temporary
solution that saves dollars and alleviates disruption of
operations.
Centralized Softwares

One emerging trend in maintenance management

technology is the use of multi-functional software
applications.
Nowadays, managing the operations of a large
company or factory can be challenging for one
person to handle. Even a skilled maintenance
manager may find it difficult to keep up with the
different operational branches. The pace of
transactions is also speeding up. Thus, it’s vital for
any business to utilize technological tools that can
help make various tasks more manageable.
Nowadays, various maintenance software can
provide updates in real-time and track changes in
multiple departments of an operational facility. In
addition, using software to apply maintenance
management best practices can lessen mistakes or
delays within a company. It can also create one
source for all the information you need and organize
it for easier access.
Most software tools used by various businesses have
preventive maintenance management features,
logistical analytics, and a work order management
system. However, you should remember that
maintaining a manufacturing business also involves
the participation of your personnel and your ability
to oversee any problems that may arise. Thus, it
would be best not to rely solely on a program to keep
your enterprise’s processes running smoothly.
Different Types of Maintenance suitable
in Garment Industry
Preventive and Planned Maintenance
Maintenance should be a routine job for the
garment manufacturing industry. Every
factory assigns a maintenance team to
ensure the smooth functioning of the
processes. The maintenance team makes a
Schedule and takes preventive action.
Proper maintenance ensures long-lasting
service.
It is designed for day-to-day maintenance
like cleaning, inspection, lubrication, and
retightening to retain the healthy condition of
the equipment
Plan and schedule the maintenance work w/o
interruption in production schedule improves
availability
The planned maintenance reduces any extra
cost.
Some of the Preventive Maintenance work
includes
Machine Cleaning (every shift)
Regular Lubrication and Oiling
Alignment and Re-tightening
Routine Maintenance (Periodic
Inspection)
Constant Servicing
Turn off the power switch,
Advanced sensors (Predictive
Maintenance)
Sensors are used in the garment industry to
find out the errors in the process
An example of it includes the traffic light system used
in machines which helps us to know which machine
is not working properly
This can be taken to a new level with the help of
Artificial Intelligence and Data Analysis by predicting
the breakdown of the machine in advance
This will not only ensure smooth production but will
also avoid delay and reduce cost.
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maintenance-in-textile/

Methods, "Maintenance Management System In Apparel Industry| Garment

Manufacturing" (21-09-2022) https://methodsapparel.com/blog/maintenance-
management/

Mishra, R.C., Pathak,K.,(August, 2013). "Maintenance Engineering and

Management" II Edition. (20-09-2022)

Srivastava, S.K., (2007). "Maintenance Engineering and Management". (20-09-

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