 Less forgiving of errors in estimating loads or of deviations from specifications during

manufacture and installation.

5.4.4 Selection of Lubricant Type

Fig. 5.3: Lubricant selection.

Load and speed are two major factors (as shown in Fig. 5.3) which affect selection of lubricants
environment and sealing requirements are additional factors which affect lubricant selection.
Apparent area, material conductivity and friction coefficient decide the operating temperature.

5.4.5 Laboratory Methods for Testing Lubricants

Typical tests include oil viscosity, viscosity index, atomic emission spectroscopy, Fourier
transform infrared (FTIR) spectroscopy, water contamination, pH paper and particle counts.
Finally, there is testing used to monitor new oils in storage. Many are unaware that lubricants in
storage have a shelf life (https://onlinelibrary.wiley.com/doi/10.1002/9783527610341.ch18).

Review Questions

 What are the consequences of wear?

 What are the main purposes of lubrication?
 Give con additives and their function? What is the function of antioxidants and corrosion
inhibitors; Dispersant additives and detergents ?

Skill development

Garage Visit/Road construction company visit: Get the information for the types Of Lubricants Used
in Automobiles and other machinery?

MECE5109 Maintenance Management Dr. Tsapi Kevin

DEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGINEERING (MIE)
NAHPI Page 27
Lecture # 4: Maintenance planning and
Scheduling
4.1 Maintenance planning

Planning of maintenance jobs basically deals with answering two questions, ‗what‘ and ‗How‘
of the job; ‗what activities are to be done?‘ and ‗how those jobs and activities are to be done?‘
While answering these two questions, other supplementary questions are to be answered, e.g.,
‗where the jobs is to be done?‘ and ‗why the job is to be done?‘ etc., but all these will be
helping in developing ‗what‘ and ‗how‘ of the job. It is very essential that engineering
knowledge must be applied extensively to maintenance jobs for development of appropriate job
plans using most suited techniques, tools materials and special facilities etc.

As the job planning forms the basic foundations, over which the efficiency and cost of actions
depends, persons responsible for job planning should have adequate capabilities, such as,
knowledge about jobs and available techniques, facilities and resources, analytical ability,
conceptual logical ability and judgmental courage etc.

 Steps of Job Planning

The main steps to be followed for proper job planning are:

1. Knowledge base: It includes knowledge about equipment, job, available techniques,

materials and facilities.
2. Job investigation at site: It gives a clear perception of the total jobs.
3. Identify and document the work: Knowing the earlier two steps and knowing the needs
of preventive, predictive and other maintenance jobs.
4. Development of repair plan: Preparation of step by step procedures which would
accomplish the work with the most economical use of time, manpower and material.
5. Preparation tools and facilities list indicating the needs of special tools, tackles and
facilities needed.
6. Estimation of time required to do the job with work measurement technique and
critical path analysis.

4.2 Maintenance scheduling

Scheduling is the function of coordinating all of the logistical issue around the issues regarding
the execution phase of the work. Scheduled of maintenance jobs basically deals with answering
two questions—‗Who‘ and ‗When‘ of job, i.e., ―who would do the job‖ and ―when the job
would be started and done‖.

Effective scheduling essentially needs realistic thinking, based on substantial data and records.
Majority of scheduling work needs to occur in areas such as overhead labour hours safety and

MECE5109 Maintenance Management Dr. Tsapi Kevin

DEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGINEERING (MIE)
NAHPI Page 28
toolbox meetings, break times and training times etc. Addition of corrective and approved
improvement actions as dictated by the prioritization system and operations plan etc.

 Requirements for Schedulers

A scheduler should have knowledge about job, techniques, facilities, analytical ability and
judgmental courage. The scheduler must obtain information about following facts, before
starting his job:

1. Manpower availability by trade, location, shift, crew arrangement and permissible

overtime limit etc.
2. Man hour back log on current or unfinished jobs.
3. Availability of the equipment or area where the work has to be performed.
4. Availability of proper tools, tackles, spares, consumables, structural and other required
materials.
5. Availability of external manpower and their capabilities; these may be from other shops/
departments of the plant or from contractors (local, nearby, ancillary etc).
6. Availability of special equipments, jigs/fixtures, special lifting and handling facilities and
cranes etc. This should also include labour and time saving devices like pneumatic
hammers and excavators etc.
7. Starting date of the job; also often completion time of total job is predetermined and, in
that case, resources are to be arranged accordingly.
8. Past schedules and charts (updated) if the same job has been done earlier, etc.

4.3 Maintenance schedule techniques

Different types of schedules are made suiting the respective job plans and different techniques
are used for making and following those schedules. The first step of all scheduling is to break the
job into small measurable elements, called activities and to arrange them in logical sequences
considering the preceding, concurrent and succeeding activities so that a succeeding activity
should follow preceding activities and concurrent activities can start together. Arranging these
activities in different fashion makes different types of schedules. They are as follows:

1. Weekly general schedule is made to provide weeks worth of work for each employee in
an area.
2. Daily schedule is developed to provide a day‘s work for each maintenance employee of
the area.
3. Gantt charts are used to represent the timings of tasks required to complete a project.
4. Bar charts used for technical analysis which represents the relative magnitude of the
values.
5. PERT (Project Evaluation and Review Technique)/CPM (Critical Path Method) are
used to find the time required for completion of the job and helps in the allocation of
resources.

MECE5109 Maintenance Management Dr. Tsapi Kevin

DEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGINEERING (MIE)
NAHPI Page 29
4.4 Planning and Scheduling Efficiency

Typical Job Planned On-the-Run (Time)

 The ―Planner/Scheduler‖ role is a skilled position!

4.5 Planning of the spares stock and Inventory control

Spares stock management plays an important role in achieving the desired plant availability at an
optimum cost. Industries nowadays are going for capital intensive, mass production oriented, and
highly improved technology. They cannot afford to have downtime for such plant and
machinery. Non-availability of spare parts, as and when required for repairs, may contribute to as
much as 50% of the total down time. In addition, the cost of spare parts is more than 50% of the
total maintenance cost in the industry. While maintenance department complains of the non-
availability of the spare parts to meet their requirement, finance department faces the problem of

MECE5109 Maintenance Management Dr. Tsapi Kevin

DEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGINEERING (MIE)
NAHPI Page 30
increasing locked up capital in spare parts inventory. This is why spare parts management is
essential in any organisation.

The unique problems faced by the organisation in controlling/managing the spare parts include
an element of uncertainty to know when a part is required and the quantity that is required. This
is because the failure of a component, either due to wearing out or due to other reasons, cannot
be predicted accurately. Moreover, spare parts may not be easily available in the market as they
may not be fast moving items. The original equipment manufacturer has to supply the spares in
most of the cases, may have introduced new models and phased out the old models. Hence, the
spares for old models may not be readily available especially for imported equipment as the
design changes are taking place faster in the developed countries. Furthermore, the number and
variety of spare parts are too large making the close control more and more tedious.

The objective of spare parts management is to ensure that spares are available at the right price,
right quality, right quantity and at the right time for maintenance and repairs of the plant and
machinery. There is a need for systematic actions while managing spare parts as given below:

 Identification of spare parts

 Forecasting of spare parts requirement
 Inventory analyses
 Formulation of selective control policies for various categories
 Development of inventory control systems
 Stocking policies for capital & insurance spares
 Stocking policies for rotable spares or sub- assemblies
 Replacement policies for spare parts
 Spare parts inspection
 Indigenisation of spares
 Reconditioning of spare parts
 Establishment of spare parts bank
 Computerization of spare parts management.

Every organisation should proceed systematically and establish an effective spare parts
management system. For the spare parts that are very expensive and those that are to be
imported, it is essential that the useful life for such spares is extended by appropriate applications
of reconditioning and repair techniques.

Review Questions

1. What is maintenance planning?

2. What is scheduling?
3. Explain the steps of job planning.
4. What are the requirements of schedules?
MECE5109 Maintenance Management Dr. Tsapi Kevin
DEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGINEERING (MIE)
NAHPI Page 31
 5. Discuss Planned vs. On The Run typical maintenance Craftsman‘s Day.
6. Discuss maintenance without planning and scheduling vs. maintenance with planning and
scheduling.
7. What is a Gantt charts? Why Is It Important?
8. What is the difference between PERT and CPM?

Skill development

Gantt charts : Create Your Own Gantt Charts using Excel

MECE5109 Maintenance Management Dr. Tsapi Kevin

DEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGINEERING (MIE)
NAHPI Page 32