Operations Management

3-Lecture per week

1-Tutorial

K Vivek Chawla
 Operations Management
•Industrial Maintenance – Concepts of Maintenance,
Organization for Maintenance department,

•Types of Maintenance-Preventive, Breakdown and

Corrective Maintenance, Failure Analysis,

•Maintenance Performance, Replacement policies of

machines.

K Vivek Chawla
 Operations Management
•Industrial Maintenance – Concepts of Maintenance,

Maintenance:-
All actions appropriate for retaining an item/part/equipment
in, or restoring it to, a given condition.

Maintenance concept:
A statement of the overall concept of the item/product specification
or policy that controls the type of maintenance action to be
employed for the item under consideration.
K Vivek Chawla
 Operations Management
•Industrial Maintenance – Concepts of Maintenance,
Maintenance plan:
A document that outlines the management and technical
procedure to be employed to maintain an item; usually describes
facilities, tools, schedules, and resources.
Reliability:
The probability that an item will perform its stated function
satisfactorily for the desired period when used per the specified
conditions.
Maintainability:
The probability that a failed item will be restored to adequately
working condition. K Vivek Chawla
 Operations Management
Organization for Maintenance department
A maintenance department perform following functions

• Planning and repairing equipment/facilities to acceptable standards

• Performing preventive maintenance; more specifically, developing

and implementing a regularly scheduled work program for the
purpose of maintaining satisfactory equipment/facility operation as
well as preventing major problems

K Vivek Chawla
 Operations Management
• Preparing realistic budgets that detail maintenance personnel and
material needs.

• Managing inventory to ensure that parts/materials necessary to

conduct maintenance tasks are readily available.

• Keeping records on equipment, services, etc.

• Training maintenance staff and other concerned individuals to

improve their skills and perform effectively

• Reviewing plans for new facilities, installation of new equipment,

etc., K Vivek Chawla
 Operations Management
The four guidelines useful in planning a maintenance
organization are:

1. Establish reasonably clear division of authority with

minimal overlap,
2. Optimize number of persons reporting to an individual,
3. Fit the organization to the personalities involved, and
4. Keep vertical lines of authority and responsibility as
short as possible.

K Vivek Chawla
 Operations Management
First considerations in planning a maintenance
organization is to find….

• What is advantageous to have a centralized or

decentralized maintenance function?

• Centralized maintenance serves well in small- and

medium-sized enterprises housed in one structure, or
service buildings located in an immediate geographic
area.
K Vivek Chawla
 Operations Management
Benefits of centralized maintenance.
• More efficient compared to decentralized maintenance.
• Fewer maintenance personnel required.
• More effective line supervision.
• Specialized maintenance persons.
• Permits procurement of more modern facilities.
• Generally allows more effective on-the-job training.

K Vivek Chawla
 Operations Management
Drawbacks of centralized maintenance.
• Requires more time getting to and from the work area or
job
• No one individual becomes totally familiar with
complex hardware or equipment
• More difficult supervision because of remoteness of
maintenance site from the centralized headquarters
• Higher transportation cost due to remote maintenance
work

K Vivek Chawla
 Operations Management
•Types of Maintenance

•Preventive

•Corrective

•Brake-Down

K Vivek Chawla
 Operations Management
Preventive maintenance (PM) is, care, servicing and
maintenance carried out to keep equipment/facilities in
satisfactory operational state by doing:
• Systematic inspection,
• Detection of faults, and
• Correction of incipient failures either prior to their
occurrence or prior to their development into major
failure.

K Vivek Chawla
 Operations Management
Main objectives of PM are to:
• Enhance capital equipment productive life,
• Reduce critical equipment breakdowns,
• Allow better planning and scheduling of needed
maintenance work,
• Minimize production losses due to equipment failures,
and
• Promote health and safety of maintenance personnel

K Vivek Chawla
 Operations Management
There are seven elements of PM
1. Inspection:
Periodically inspecting materials/items to determine their
serviceability
2. Servicing:
Cleaning, lubricating, charging, preservation, etc., of
items/ materials periodically to prevent the occurrence of
incipient failures
3. Calibration:
Periodically determining the value of characteristics of an
item by comparison to a standard K Vivek Chawla
 Operations Management
There are seven elements of PM
4. Testing: Periodically testing or checking of Machine.

5. Alignment: Making changes to an item’s specified

variable elements.

6. Adjustment: Periodically adjusting specified variable

elements of material

7. Installation: Periodic replacement of limited-life items

or the items experiencing time cycle or wear degradation
K Vivek Chawla
Operations Management

K Vivek Chawla
 Operations Management
Corrective Maintenance
• Defined as the remedial action carried out due to
failure or deficiencies discovered during preventive
maintenance, to repair an equipment/item to its
operational state.

• Corrective maintenance is an unscheduled maintenance

action, performs unpredictable maintenance needs that
cannot be preplanned or programmed on the basis of
occurrence at a particular time.

K Vivek Chawla
 Operations Management
Corrective Maintenance
Corrective maintenance may be classified into five major
categories
1. Fail-repair,
2. Salvage,
3. Rebuild,
4. Overhaul, and
5. Servicing.

K Vivek Chawla
 Operations Management
Corrective Maintenance

K Vivek Chawla
 Operations Management
Corrective Maintenance
Fail-repair: The failed item is restored to its operational
state.

Salvage: Disposal of nonrepairable material and use of

salvaged material from nonrepairable equipment/item in
the repair, overhaul, or rebuild programs.

Rebuild: Restoring an item to a standard as close as

possible to original state in performance, life expectancy,
and appearance. K Vivek Chawla
 Operations Management
Corrective Maintenance
Overhaul:
Restoring an item to its total serviceable state as per
maintenance serviceability standards.

Servicing:
Servicing may be needed because of the corrective
maintenance action, for example, engine repair can lead to
crankcase change, welding, etc.

K Vivek Chawla
 Operations Management
Breakdown Maintenance
• Repair is undertaken only after failure of system.
• Equipment is allowed to run till it fails.
• - Small factories where equipment are very small and
doesn’t use special tools
• - Isn’t suitable for big industries

K Vivek Chawla
 Operations Management
Failure Analysis

K Vivek Chawla