MAINTENANCE MANAGEMENT

Definition:

A formal definition of maintenance is “that

function of manufacturing management that
is concerned with day to day problem of
keeping the physical plant in good operating
condition”
 Objectives:
• Minimize loss of productive time
• Minimize repair time & cost
• Keep productive assets in working
condition
• Minimize accidents
• Minimize total maintenance cost
• Improve quality of products
 Importance:
• Dependability of service
• Assured quality
• Prevent equipment failure
• Cost control
• Huge investment in equipment
 Areas of Maintenance:
1. Civil maintenance- Building construction and
maintenance, maintaining service facilities
2. Mechanical Maintenance- Maintaining
machines and equipments, transport vehicles,
compressors and furnaces.
3. Electrical Maintenance- Maintaining electrical
equipments such as generators, transformer,
motors, telephone systems, lighting, fans, etc.
 ORGANISATION MAY USE ANY OR ALL THE
FIVE TYPES OF MAINTENANCE

• Breakdown maintenance or corrective

maintenance
• Preventive maintenance
• Predictive maintenance
• Routine maintenance
• Planned maintenance
BREAKDOWN MAINTENANCE

• Occurs when there is a work stoppage due

to machine breakdown
• Maintenance becomes repair work
• Seeks to get the equipment back into
operation as quickly as possible
• To control the investment in replacement
spare machines.
 Preventive management

It is undertaken before the need arises and aims to minimize the possibility of un -
anticipated production interruption or major breakdowns.
• Predictive maintenance:
In this, sensitive intruments(eg.vibration
analysers,amplitude meters,audio
gauges,optical tooling and resistance gauges)
are used to predict trouble. Conditions can be
measured on a continuous basis and this
enables the maintenance people to plan for
an overhaul.
• Routine maintenance: this includes activities
such as periodic
inspection,cleaning,lubrication and repair of
production equipments after their service life.
• Planned maintenance: it involves the
inspection of all plant and
equipments,machinery,buildings according to
a predetermined schedule in order to service
overhaul, lubricate or repair, before actual
break down or deterioration in service occurs.
• Opportunistic Maintenance: – In multi component system, several failing components,
often it is advantageous to follow opportunistic maintenance. When an equipment or system is
taken down for maintenance of one or few worn out component, the opportunistic
maintenance can utilize for maintaining or changing other wear out components, even though
they are not failed. -It is actually not a specific maintenance system, but its a system of
utilizing an opportunity which may come up any time.

• Corrective Maintenance – Maintaining action for correcting or restoring failed unit.

- Very vast scope for small actions like adjustment, minor repairs to redesign of equipments
- Generally once taken and completed fully Usually carried out in four steps :
• 1st step : collection of data, information and Analysis
• 2nd step : identifying the causes
• 3rd step : find out the best possible solution to illuminate likely causes
• 4th step : Implement those solutions
• Emergency maintenance: It is carried out as fast as possible in order to bring a failed machine or facility to a safe and
operationally efficient condition.

• Routine maintenance which includes those maintenance activities that are repetitive and periodic in nature such as
lubrication, cleaning, and small adjustment.
• Running maintenance which includes those maintenance activities that are carried out while the machine or equipment
is running and they represent those activities that are performed before the actual preventive maintenance activities take place.
• Opportunity maintenance which is a set of maintenance activities that are performed on a machine or a facility when an
unplanned opportunity exists during the period of performing planned maintenance activities to other machines or facilities.
• Window maintenance which is a set of activities that are carried out when a machine or equipment is not required for a
definite period of time.
• Shutdown preventive maintenance which is a set of preventive maintenance activities that are carried out when the
production line is in total stoppage situation.
• Remedial maintenance which is a set of activities that are performed to eliminate the source of failure without
interrupting the continuity of the production process.
• Deferred maintenance which is a set of corrective maintenance activities that are not immediately initiated after the
occurrence of a failure but are delayed in such a way that will not affect the production process.
• Shutdown corrective maintenance which is a set of corrective maintenance activities that are
performed when the production line is in total stoppage situation.
• Design-out maintenance which is a set of activities that are used to eliminate the cause of
maintenance, simplify maintenance tasks, or raise machine performance from the maintenance point of
view by redesigning those machines and facilities which are vulnerable to frequent occurrence of failure
and their long term repair or replacement cost is very expensive.
• Engineering services which includes construction and construction modification, removal and
installation, and rearrangement of facilities.
• Shutdown improvement maintenance which is a set of improvement maintenance activities that are
performed while the production line is in a complete stoppage situation.
• Predictive maintenance is a set of activities that detect changes in the physical condition of equipment (signs of failure)
in order to carry out the appropriate maintenance work for maximising the service life of equipment without increasing the
risk of failure.
It is classified into two kinds according to the methods of detecting the signs of failure:
– Condition-based predictive maintenance
– Statistical-based predictive maintenance
• Condition-based predictive maintenance depends on continuous or periodic condition monitoring equipment to detect the signs
of failure.
• Statistical-based predictive maintenance depends on statistical data from the meticulous recording of the stoppages of the in-
plant items and components in order to develop models for predicting failures.

• The drawback of predictive maintenance is that it depends heavily on information and the correct interpretation of the
information.
• Some researchers classified predictive maintenance as a type of preventive maintenance.
• The main difference between preventive maintenance and predictive maintenance is that predictive maintenance uses
monitoring the condition of machines or equipment to determine the actual mean time to failure whereas preventive
maintenance depends on industrial average life statistics.
 CONTROL OF MAINTENANCE

1. Authorized by an official
2. Maintenance schedule
3. Issue materials against proper authorization
4. Maintenance budgets
5. Equipment records
 Issues:
• how much maintenance is needed?
• What size maintenance crews must be
used?
• Can maintenance be sub-contracted?
• Should maintenance staff be covered by
wage incentive schemes?
• Can effective use be made of computers
for analyzing and scheduling activities?
 Preventive Maintenance:

Preventive maintenance is undertaken before

the need arises and aims to minimize the
possibility of un-anticipated production
interruptions or major breakdowns.
It consists of:

• Proper design and installation of equipment

• Periodic inspection of plant and other
equipments
• Repetitive servicing and overhaul of
equipment
• Adequate lubrication, cleaning and painting
 Benefits:
• Greater Safety
• Decreased Production Down Time
• Fewer large Scale & Repetitive Repairs
• Less Cost for Simple Repairs
• Less Standby Equipment Required
• Better Spare parts Control
• Proper Identification f Items
 Maintenance Scheduling:
Scheduling refers to timing and sequences of
operations.

It is an important segment of the production

planning & control activity as well as the
service operations like plant maintenance
 Importance of scheduling:

• Facilitates optimum use of highly paid

maintenance staff

• Equipments can be utilized effectively

• Eliminates undue interruptions in the

production flow
• Eliminates chances of sudden breakdown

• Facilitates proper sequence in maintenance

service
 Reliability:

• Component Reliability

• Product Reliability
 Component Reliability
Definition:

• It is the probability that a part or a component

will not fail in a given time period or number
of trails under ordinary conditions of use.
•
MEASUREMENT
Component reliability is usually measured by reliability,
failure rates and mean time between failures, i.e.

CR=1-FR
number of failures
Where FR = number of components
tested

number of failures
FRn = unit-hrs of operation of the
component

1 unit-hr of operation
MTBF = FRn = No. of failures
 PRODUCT RELIABILITY OR
SYSTEM RELIABILITY
When components or parts are combined into a
larger system, such as a machine or a product,
the combined reliability of all the components or
parts form the basis for product or system
reliability
 CALCULATION OF PRODUCT OR
SYSTEM RELAIBILITY
• When critical components interact during
the operation of the product or system, the
reliability of the product or system is
determined by computing the product of
the reliabilities of all the interacting critical
components.
SR = CR1*CR2*…..*CRn
 TURN OUT A RELIABLE PRODUCT
FIVE KEY AREAS
• Design of the product
• Production
• Measurement and testing
• Maintenance and
• Field of operation.
 Conclusion:
• To ensure effective implementation of
activities, it is important that the production
facilities need to be maintained in good
working condition.
• Reduces cost, machinery breakdown etc
• Quality assurance

Therefore maintenance management is an

important aspect for any organisation
• MAINTENANCE SAFETY-RELATED FACTS,
FIGURES, AND EXAMPLES, AND REASONS
FOR SAFETY PROBLEMS IN MAINTENANCE
Accidents occurring during maintenance account for a significant proportion of the
overall accidents.
There are various reasons for safety related problems in maintenance. Some of
the important reasons are shown in Fig.
• SAFETY AND MAINTENANCE TASKS
• In addition to the general safety considerations, other factors that influence the safety
• dimensions of maintenance tasks include:
• • Numerous maintenance tasks or jobs are in direct response to the needs
• of working safely. Consequently, safety needs augment maintenance tasks
• or jobs.
• • Numerous maintenance tasks or jobs are hazardous and lead to hazardous
• solutions. Thus, maintenance work is a cause of safety-related problems.
• The first item may be interpreted as one result of an effective safety management
• system. However, the second item requires further review. Some aspects of maintenance
• work that give it this dubious safety reputation are as follows:
• 9
• • Numerous maintenance tasks occur infrequently, e.g., machinery failures,
• thus fewer opportunities to discern safety-related problems and to introduce
• remedial measures.
• • Maintenance work performed in unfamiliar surroundings means that hazards
• such as rusted handrails, broken light fittings, and missing gratings
• may pass unnoticed.
• • Difficulty in maintaining regular communication with workers in some
• maintenance tasks.
• • Some maintenance work may require performing tasks such as disassembly
• of corroded parts, or manhandling cumbersome heavy parts in poorly
• lit areas and confined spaces.
• • Disassembling previously working machinery, thus working under the risk
• of releasing stored energy.
• • Sudden need for maintenance work, allowing limited time to prepare.
• • Performance of maintenance work inside or underneath machines such as
• air ducts, pressure vessels, and large rotating machines.
• • Performance of maintenance work at odd hours, in remote locations, and
• in small numbers.
• • Need to transfer heavy and bulky materials from a warehouse to the maintenance
• workplace, sometimes using lifting and transport equipment well
• outside a strict maintenance regime.
• GUIDELINES FOR EQUIPMENT DESIGNERS
• TO IMPROVE SAFETY IN MAINTENANCE
• One way to improve maintenance safety is to minimize the need for maintenance
• in systems or equipment at the design stage. If the need for maintenance cannot be
• eliminated, the designers should follow guidelines for improving maintenance safety
• as follows:
• 17
• • Simplify the design as much as possible. Complexity generally adds to
• maintenance problems.
• • Provide fail-safe designs to prevent injury or damage in the event of a
• failure.
• • Develop designs or procedures to minimize the occurrence of maintenance
• errors.
• • Minimize or eliminate the need for special tools/equipment.
• • Incorporate devices or other measures to permit early detection or prediction
• of potential failures so that maintenance can be carried out prior
• to actual failure with somewhat lower risk of hazard.
• • Design for easy accessibility so that items or units requiring maintenance
• are not difficult to remove, replace, service, or check.
• • Develop the design such a way to reduce the probability of maintenance
• workers being injured by electric shock, contact with a hot surface, escaping
• high-pressure gas, etc.
• • Eliminate the opportunity to perform maintenance or adjustments close
• to hazardous operating equipment or parts.
• • Provide guards against moving parts and interlocks to block access to
• hazardous locations.
• • Consider the typical human behaviors presented in Table
• MAINTENANCE PERSONNEL SAFETY
• Usually, emphasis is placed on designing safety into machines rather than on the
• safety of the operators, maintainers, etc. On occasion, more protection is required
• for maintenance workers beyond the safety designed into machines or processes.
• Two important areas of maintenance worker safety are respiratory protection and
• protective clothing. Figure 9.3 shows four areas in which respiratory protection is
• required. The protective clothing includes items such as:
• 9
• •
• Ear defenders:
• These are necessary where machine or process noise can
• damage maintenance workers’ ears.
• • Boots and toecaps: Well-fitting boots with steel toecaps can reduce the
• risk of injury in situations such as dismantling used equipment where
• heavy metal parts are difficult to hold and are likely to slip and drop on
• exposed feet.
• • Helmets and hard hats: These are useful to protect maintenance workers
• from head injury.
• • Gloves: These are important to protect hands from injury when performing
• various types of maintenance tasks.
• • Goggles, visors, screens, and safety glasses: These items protect eyes
• from flying chips, sparks, chemical sprays, jetted hydraulic fluid, etc.
 UNITII
• The results obtained from the evaluation
process help the organization to determine
whether its information systems are effective
and efficient or otherwise. The process of
monitoring, evaluating, and modifying of
existing information systems to make required
or desirable improvements may be termed as
System Maintenance.
• Maintainability is defined as the probability of performing a successful repair
action within a given time. In other words, maintainability measures the ease and
speed with which a system can be restored to operational status after a failure
occurs. This is similar to system reliability analysis except that the random variable
of interest in maintainability analysis is time-to-repair rather than time-to-failure.
For example, if it is said that a particular component has a 90% maintainability for
one hour, this means that there is a 90% probability that the component will be
repaired within an hour. When you combine system maintainability analysis with
system reliability analysis, you can obtain many useful results concerning the
overall performance (availability, uptime, downtime, etc.) that will help you to
make decisions about the design and/or operation of a repairable system.