Engineering Maintenance

Prepared by Tesfaye S.
 CHAPTER TWO
OPERATING POLICIES OF EFFECTIVE MAINTENANCE

Contents
The four general Policies categories
 Policies with respect to work allocation
 Policies with respect to work force
 Policies with respect to interplant relations
 Policies with respect to control
 Introduction

• What do we mean by effective maintenance?

• What are operating policies of effective maintenance?

Effective maintenance?

 Effective maintenance refers to the practices, procedures, and processes implemented to

ensure that equipment, systems, or assets operate efficiently, reliably, and safely aiming to
minimize downtime, reduce cost, and extend the lifespan of assets.

 Effective maintenance strategies combine regular inspections and timely repairs to

identify and address potential issues before they escalate into major problems.
Cont..

Effective maintenance is maintenance with:

 Scheduled time table

 Fully equipped spare parts

 Preventive maintenance principles

 Operators will participate in routine service activities

 Skilled and experienced man power

Maintenance policy is a statement of principle used to achieve maintenance objectives

and guide maintenance management decision making.
 Policies with respect to work allocation

To schedule or not to schedule?

• It is generally accepted that, in any maintenance department where there are more than
10 men and more than two or three crafts, other than day-to-day allocation of work by
foremen, planning can result an improved efficiency.

• As the size of the maintenance organization increases, the extent to which work planning
can be formalized and the amount of time that should be spent on this working activity's
are increased. Planning is necessary to maximize overall efficiency.
Scheduling

• Scheduling is when to do the job.

• Scheduling is the process by which required resources are allocated to specific jobs at
a time, and make the associated equipment or job site accessible.

• The goal of scheduling is to ensure that resources are available at a specific time when
the equipment is available.
Aspects considered before scheduling

• Work unit/components: to set what amount of human force to how much time is needed
to finish specific work.

• Size of jobs scheduled: To what extent it is large or small.

• Percent of total work load scheduled: Recognize the inability of any maintenance
engineering department to anticipate all jobs, especially those of an emergency nature.

• A portion of the available work force is left free for quick assignment to emergency jobs
or other priority work not anticipated at the time of scheduling.

• Lead time for scheduling: The length of time covered by the schedule.
Cont..

Selection and implementation of a scheduling system

• Implementing proper planning and scheduling can improve productive maintenance time
from the 25 to 35% of a typical organization without planning to 50 to 50%, almost
doubling the ability to get work completed.
Cont……

• Flow-of- work requests: This request may have the form of a work description or job
ticket, listing manpower or equipment requirement, or it can be in the form of a work
sheet which consists full information either by written way or verbal communication.

• Before any scheduling program can be initiated, the method of requesting work from
the maintenance department should be formalized.
Cont…

• Coordinating and Dispatching. In the execution of an effective scheduling system it is

necessary to compromise with the practical considerations of getting the work done, and
done economically.

• Determination of Priority. In any maintenance organization which is efficiently

manned, the work load, in terms of quantity or timing, exceeds the availability of men
and/or equipment.

• For this reason the problem of defining the order in which the work is to be carried out,
or establishing priority, exists and is an important factor in scheduling
Policies with respect to work force

Own work force or outside contractors?

• The primary factor in deciding whether to use an outside contractor is cost. Is it cheaper

to staff internally for the performance of

The type of work involved,

The amount of work involved, and

The expediency with which this work must be accomplished?

Cont…

• In studying these relative costs it is not sufficient to consider the maintenance cost alone.

• The cost to the company, including downtime and quality of performance, must also be

considered.

• To establish, supervise, and maintain a group of men in any specific craft means a

continuing expense over the wages paid the men

 Policies with respect to intraplant relations

• Participation by Maintenance Personnel in Selection of Production Equipment.

• In some plants one engineering department handles all phases of engineering activity
from design through construction and maintenance.

• In the majority of plants, the construction of major facilities or addition of major

equipment is engineered by outside engineering contractors.
 Policies with respect to control

• Communications

A starting point in analyzing the problem of communications and the types to be

used is a study of the sort of information to be transmitted and the amount of detail
involved through these three major channels:
 Up through the supervisory organization

 Down through the supervisory organization

 Laterally across the same level of organization

Use of standard-practice sheets and manuals

 There are many forms of standard-practice sheets, or standard job-instruction sheets,

and instruction manuals used in maintenance departments.

 They are excellent devices for planning work, ordering materials, improving estimating

accuracy, and training crafts personnel.

Cont..

• A plant having a large number of identical machines or of machines having identical

components which require a repetitive type of repair can justify more detailed standard-

practice sheets than a plant with very little duplication of equipment or maintenance jobs.

• The need for standard-practice sheets also varies with the complexity of the repair and with

the degree of skill and the experience of the men performing the work.
 yo u
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 Self assessment questions/Quiz

1. What is maintenance and its objective?

2. How often should apparel machineries be serviced?

3. What are the best practices for maintaining sewing machines in a garment
factory?

4. What is the importance of a proper maintenance in garment machinery?

5. What are the maintenance activities carried out in apparel machinery?
 Quiz 1

1. What is maintenance and its objective?

2. What is effective maintenance and how we can achieve it?

3. What are the maintenance activities you observed in our lab?

4. What is the importance of having a proper maintenance in

garment machineries?