Maintenance Management &

Reliability Engineering

Maintenance Management
 Maintenance
• Everything in life which runs or which is run for
some purpose needs some attention, some
efforts to keep it in desired condition. Such
special efforts are generally called as
maintenance.
• Examples – Well countless examples where you
see maintenance in day-to-day life. When you
go to gym in the morning it’s to maintain your
health/physique. You get your bike serviced to
maintain it. You visit some peaceful place like
temple to maintain your soul.
 Maintenance
• Maintenance is vital. In a bigger picture it
is part of risk management to deal with
operational risks.
• It can reduce downtime or degradation of
a system to a great extend
• But at the same time keep in mind that
maintenance is not a magic. “wear and
tear, degradation, aging out” of any part of
the system or the system itself is the truth
of the life.
 Industrial System
• Industry produces some kind of output
(primary , secondary or tertiary) from some
raw material
• We know
Industrial System

Application of energy in Product

Raw Waste
various form (Process) (as per or
Material +
predefined scrap
specifications)
 Industrial System
• Industrial system is composed of number of
elements which may differ depending on the
type of industry or production
– Land and building
– Human resource
– Plant and machinery
– Other civil facilities like roads, storage tank etc
– Production Tools
– Support tools and equipment like communication
devices, vehicles for material movement
– IT systems (Hardware, software, network etc)
 Industrial Maintenance
• All these elements need to be maintained.
That means systematic efforts must be
taken to keep these elements in a
condition that is desirable for the
manufacturing and business process to
run smoothly.
• Out of these “Human resource” is unique,
complicated and is handled & maintained
by a separate division. The HR activities
are special category of maintenance
activity.
 Industrial Maintenance
• The scope of the subject excludes
maintenance of human resources as it is
always an exclusive subject for study and
research.
• Maintenance was traditionally divided
mainly into three categories.
– Mechanical
– Electrical
– Civil
 Industrial Maintenance- Divisions
• Civil Maintenance – deals with repair of
buildings and other civil infrastructure
inside or outside plant which may include
foundation of machine etc, internal roads,
underground channels for supply of water
or electricity, concrete storage tanks for
water or other liquids, water supply.
• While the scope of the civil maintenance
can be easily identified it is not the case
with the other two divisions
 Industrial Maintenance- Divisions
• Mechanical maintenance – deals with
repair and conditioning of different kind of
machines, equipments for material
handling and movement (like cranes,
forklifts etc), pneumatic and hydraulic
systems.
• A quick question – A drill bit is worn out; is
it maintenance responsibility to arrange for
a new one ?
Ans - No. Arranging tool is responsibility of
production planning.
 Industrial Maintenance- Divisions
• Electrical maintenance – Deals with repair and
conditioning of equipments involved in electric
supply (switch, fuse, generator ) electric
equipments like motor, fan, light, air-
conditioning. While this scope seems to be fairly
clear there can be electrical faults in machines
and mechanical faults in electric equipments like
AC.
• Hence clear division of scope is not possible.
People from these two divisions may have to be
cross trained or to work together.
 Industrial Maintenance- Divisions
• In modern days we now see some more
divisions under maintenance these are
described below
• Electronics Maintenance – Sophisticated
machineries in the plant demand in-house
availability of skilled personnel for
conditioning electronic components,
systems etc in machines and plant itself.
 Industrial Maintenance- Divisions
• IT Maintenance – Deals with maintenance of
hardware, software, network and on modern
industry the communication devices like IP
phone, video conferencing system etc.
• However IT division itself is considered as a
separate division which takes care of acquisition
of above described IT elements and
maintenance of it.
• If the software is not in-house developed then
the maintenance/support is required from the
respective vendor.
 Objectives of Maintenance
• Maximization of availability of equipment or
facilities
• Establishment of safe working conditions
• Reduce maintenance cost
• Prevent breakdown during operation
• Prevent rapid wear of components
• Rework due to faulty components produced by a
malfunctioning equipment is reduced.
• In a bigger picture maintenance plays role
improving predictability, meeting commitments
and gaining customer satisfaction.
 Types of Maintenance
• Broadly two categories
– Breakdown maintenance : Do nothing i.e. no
maintenance activity as long as everything is going on
well or until equipment fails. Breakdown maintenance
can’t be avoided completely but it shouldn’t be the
strategy.
– Planned maintenance : maintenance work is planned
to avoid random failures. It involves study/analysis of
types and frequencies of failures, reasons for failures,
nature of repair, amount of work needed etc. Planning
involves making decisions as what, when and by
whom etc.
 Types of Maintenance
• A quick question – Why do we plan
anything ?
– Ans : We have limited physical resources and
time and we have definite goals to achieve.
We cannot afford to waste the resources or
running out of it. Planning is systematic
approach to avoid these two things, i.e.
planning helps in utilizing resources
effectively.
• Assignment : In your own words write
down benefits and drawbacks of
“Breakdown maintenance strategy”