Maintenance

Objectives | Functions | Benefits

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Maintenance vs Organizationan objective overview

Maintenance


Organization
   

  

Keeping assets and equipment in good condition, well configured and safe to perform their intended functions; Perform all maintenance activities including preventive, predictive; corrective, overhauls, design modification and emergency maintenance in an efficient and effective manner; Conserve and control the use of spare parts and material; Modification and redesign for optimum plant performance; Operate utilities and conserve energy.

Profit maximization ; Specific quality level of service or products; Minimizing costs safe and clean environment; Human resource development.

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The Function and Responsibility

The principal responsibility of maintenance is to provide a service to enable an organization to achieve its objectives.

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The purpose

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The Limbs of Maintenance

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Role of top level management

Evaluate current personnel performance; Assess training need analysis; Design the training program; Implement the program; Evaluate the program effectiveness.

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Maintenance Performance Measurement (MPM)



Maintenance Performance Measurement (MPM) is defined as the multidisciplinary process of measuring and justifying the value created by maintenance investment, and taking care of the organizations stockholders requirements viewed strategically from the overall business perspective Management needs information of maintenance performance for planning and controlling the maintenance process. A Performance Measurement system is defined as the set of metrics used to quantify the efficiency and effectiveness of actions. A Performance Indicator (PI) is used for the measurement of the performance of any system or process.

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MPM in performance accreditation

A strategic planning tool; A management reporting tool; An operational control and monitoring tool; A change management support tool.

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Some of the measures of maintenance performances are

    

Availability, Mean time between failures (MTTF), Failure/breakdown frequency, Mean time to repair (MTTR) Production rate index.

For the process industry, machine downtime in the shop floor is one of the main issues for maintenance productivity.

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Types of maintenance
 

Total productive maintenance Preventive maintenance

 

Planned maintenance Condition based maintenance

  

Emergency or breakdown maintenance Opportunistic maintenance Redesign and modification

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Total productive maintenance

 

A company-wide team-based effort to build quality into equipment and to improve overall equipment effectiveness Total  all employees are involved  it aims to eliminate all accidents, defects and breakdowns Productive  actions are performed while production goes on  troubles for production are minimized Maintenance  keep in good condition  repair, clean, lubricate

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The seven pillars

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The base

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7 steps to TPM bliss

7 steps are implemented to progressively increase operators knowledge, participation and responsibility for their equipment 1. Perform initial cleaning and inspection 2. Countermeasures for the causes and effects of dirt and dust 3. Establish cleaning and lubrication standards 4. Conduct general inspection training 5. Carry out equipment inspection checks 6. Workplace management and control 7. Continuous improvement

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Preventive maintenance
Preventive maintenance (PM) has the following meanings: The care and servicing by personnel for the purpose of maintaining equipment and facilities in satisfactory operating condition by providing for systematic inspection, detection, and correction of incipient failures either before they occur or before they develop into major defects. Maintenance, including tests, measurements, adjustments, and parts replacement, performed specifically to prevent faults from occurring.
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Types
1.

Planned preventive maintenance (PPM) is a variety of scheduled maintenance to an object or item of equipment. Specifically, Planned Maintenance is a scheduled service visit carried out by a competent and suitable agent, to ensure that an item of equipment is operating correctly and to therefore avoid any unscheduled breakdown and downtime. Condition-based maintenance (CBM), shortly described, is maintenance when need arises. This maintenance is performed after one or more indicators show that equipment is going to fail or that equipment performance is deteriorating.

2.

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Emergency
This is the type of maintenance that is undertaken when a particular part fails or stops functioning. Occurs when the other sections fail This is an indicator to improve inspection methods
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Redesign and modification

Redesign and modification is an advanced type of maintenance or rather it is an advanced stage of all types of maintenance practices. Requires an experienced team of engineers and fabricators. As time goes by this will be an integral part of maintenance practice of any plant. It adds character to individual units customizing them and fine tuning them to the required condition.
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Advantages of a good maintenance practice

    

Reduces unplanned shut downs. Improves plant production. Improves quality. Improves plant capability. Makes continuous improvement of the practice easier

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At a glance
We discussed: 1. The objectives of maintenance and an organization; 2. Function and responsibility of maintenance; 3. Purpose of maintenance; 4. Limbs of maintenance; 5. Maintenance performance measures; 6. MPM; 7. Types of maintenance; 8. Advantages.
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