Introduction to Maintenance

By:
Manvendra Singh,
JGM/S&T/V
WHAT IS MAINTENANCE ?
 Combination of all technical and management actions
intended to retain an item in, or restore it to, a state in
which it can perform as required.

 Fixing any sort of mechanical or electrical device

which has become out of order or broken.

 Performing routine actions which keep the system in

working order or prevent trouble from arising.
Question?

 Why do we need maintenance?

 What are the costs of doing maintenance?

 What are the costs of not doing maintenance?

 What are the benefits of maintenance?

 How can maintenance increase profitability of

company?
Principle Objectives in Maintenance
 To achieve product quality and customer satisfaction
through adjusted and serviced equipment

 Maximize useful life of equipment

 Keep equipment safe and prevent safety hazards

 Minimize frequency and severity of interruptions

 Maximize production capacity – through high

utilization of facility
Problems in Maintenance

 Lack of management attention to maintenance

 Little participation by accounting in analyzing and

reporting costs

 Difficulties in applying quantitative analysis

 Difficulties in obtaining time and cost estimates for

maintenance works

 Difficulties in measuring performance

 Basic Concepts of Maintenance:

 Reliability – the system can run continuously without

failure.

 Availability – the system is ready to be used immediately.

 Maintainability – when a system fails, it can be repaired

easily and quickly (and, sometimes, without its users
noticing the failure).

 Safety – if a system fails, nothing catastrophic will

happen.

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 What Is “Failure”?

 A system is said to “fail” when it cannot meet its

promises.

 A failure is brought about by the existence of “errors” in

the system.

 The cause of an error is called a “fault”.

 Stress overcomes the “Strength”.

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Types of Fault

 Transient Fault – appears once, then disappears.

 Intermittent Fault – occurs, vanishes, reappears; but:

follows no real pattern (worst kind).

 Permanent Fault – once it occurs, only the

replacement/repair of a faulty component will allow
the desired system to function normally.

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BRANCHES OF MAINTENANCE:
 Corrective Maintenance

 Time Based Maintenance

 Condition-Based Maintenance

 Predictive Maintenance

 Reliability-Centered Maintenance
Maintenance strategies

 CM - Corrective Maintenance
– Corrective maintenance actions in case of a fault
in order to return to normal condition
– Run to failure: inspections aren’t performed.
Replacement is done when component fails.

 TBM - Time Based Maintenance

– Age replacement
– Periodic inspections
– Sequential inspections
Maintenance strategies

 CBM - Condition Based Maintenance

 Performed after one or more indicators show that

equipment is going to fail or that equipment
performance is deteriorating.

 Introduced to try to maintain the correct equipment at

the right time.

 CBM is based on using real-time data to prioritize

and optimize maintenance resources.
 Maintenance strategies

 PREDICTIVE MAINTENANCE:

 Techniques help to determine the condition of in-

service equipment in order to predict when
maintenance should be performed. This approach
offers cost savings over routine or time –based
predictive maintenance, because tasks are
performed only when warranted.
Maintenance strategies

 RCM - Reliability Centered Maintenance:

 It is generally used to achieve improvements in fields

such as the establishment of safe minimum levels of
maintenance, changes to operating procedures
strategies and the establishment of capital
maintenance regimes and plans.

 Successful implementation of RCM will lead to

increase in cost effectiveness, system uptime. And a
greater understanding of the level of risk that the
organization is presently managing.
 Maintenance measures
Strategy Measures
Inspection Servicing Repairment Renewal
Corrective - - In case of In case of
failure failure
Time based Intervally Intervally In case of Intervally
failure
Condition Periodic According to In case of According to
based inspections or condition failure condition
continuous
monitoring

Reliability- According to maintenance strategy on component base

centered
Probabilistic Periodic According to In case of According to
inspections or condition, failure condition,
continuous importance importance
monitoring and outage risk and outage risk
Corrective or Breakdown Maintenance
 Corrective or Breakdown maintenance implies that
repairs are made after the equipment is failed and
can not perform its normal function anymore

 Quite justified in small organizations where:

– Down times are non-critical and repair costs are
less than other type of maintenance
– Financial justification for scheduling are not felt
Disadvantages of Corrective Maintenance

 Breakdown generally occurs inappropriate times

leading to poor and hurried maintenance
 Excessive delay in restoration & reduces
output/efficiency
 Faster asset deterioration
 Increases chances of accidents and less safety for
both workers and machines
 More spoilt materials
 Direct loss of profit
 Can not be employed for equipments regulated by
statutory provisions e.g. Point Machines, Track
Circuits & Signalling related equipments.
 Maintenance Costs

Cost
Total Maintenance Cost

PM Cost

Breakdown Cost

Optimal Maintenance
Commitment
Maintenance Management Loop

Study preparation RAMS requirements

Failure modes and

Maintenance types
effect analysis
and intervals

Grouping of
Overall operation,
maintenance activities
Data Analysis and mainteance and repair
improvement analysis Fa
ilu
De re
via s

Re
tio
ns
str
ict
i on Maintenance and
Data- s inspection plan
base
Report Acutal maintenance
ing
and inspection
General Precautions:
 Permission shall be obtained for Engineer’s
Possession & Integrated Blocks including Power
Blocks and Shadow Power Blocks during Non-
Revenue Hours

 OHE Power Block and Shadow Power Block shall be

required in case the working zone is within a radius of
‘2’m from OHE.
General Precautions:
 No Maintenance Staff shall enter on to the Track of
any Running Line without the Permission of the
Traffic Controller and Permit To Work

 Metro Employees and Authorized Contractor's

Representatives, when on Right of Way Shall be
responsible for their own Safety and observe all
Safety Rules and Regulations during the course of
Work.
General Precautions:
 Shall not walk, stand, step or sit on Running Rails,
Points, Cover Boards, TVC Conduit, Guard Rails,
Interlocking Apparatus or Wayside Equipments.

 Shall not hang upon or lean on the sides of

Moving Vehicles, Shall not lean against the
Standing Vehicle or Equipment and shall not
board or alight on / from any Moving Vehicle.

 EPIC shall protect the area under Engineers

Possession/Integrated Block from access by
trains.