Maintenance engineering and management (Ieng 5121)

5th industrial Engineering

By G/M. T.

February 2024
Maintenance Engineering 1
 Chapter Two

Machine operation

Maintenance Engineering 2
 Introduction

 What is machine operations?

 What is maintenance of a machine ?

 How can maintenance and operation be effective and efficient?

 Effective Operation & Maintenance is one of the most cost-effective methods for ensuring
reliability, safety, and energy efficiency.

 Inadequate maintenance of energy using systems is a major cause of energy waste

 Energy losses from steam, water and air leaks, uninsulated lines, maladjusted or inoperable
controls, and other losses from poor maintenance are often considerable.

Maintenance Engineering 3
 Introduction

Definitions of Maintenance:

Maintenance is keeping something in good condition (Oxford Dictionary).

Maintenance consists of those activities required to keep a facility in original (i.e.

as-built) condition so that its designed productive capacity (or performance)
remains unchanged.

Maintenance Engineering 4
 Introduction
Good maintenance practices can generate substantial energy savings and should be
considered a resource.

Moreover, improvements to facility maintenance programs can often be

accomplished immediately and at a relatively low cost.

The Operation & Maintenance effectiveness and efficiency mainly depends on its
management, technology and cost reduction approaches

Operations and Maintenance refers to decisions and actions regarding the control
and upkeep of property

Maintenance Engineering 5
 Introduction

The operation and maintenance should do the following on the

equipment:
 Actions focused on scheduling, procedures, and work/ systems
control and optimization,
Performance of routine maintenance works , preventive, predictive,
scheduled and unscheduled actions aimed at preventing equipment
failure or decline with the goal of increasing efficiency, reliability, and
safety.
Maintenance Engineering 6
 Introduction

Operational Efficiency represents the life cycle cost-effective mix of preventive,

predictive, and reliability centered maintenance technologies

Operational efficiency refers to efficient performance of equipment calibration,

tracking or diagnosis, and computerized maintenance management capabilities

Operational efficiency of equipments targets reliability, safety, and system

efficiency.

Maintenance Engineering 7
 Introduction
Various indicators that can be used to measure the quality or effectiveness of the Operation
&Maintenance program are listed bellow:
 Energy use
 Safety record
 Capacity factor
 Backlog of corrective maintenance
 Environmental record
 Overtime worked
 Inventory control
 Work orders generated/closed out
 Staff turnover
 Absentee rate

Maintenance Engineering 8
 Introduction

A Truly Effective O&M Program Requires An Active Commitment

From Operations, Maintenance, Engineering, And Administration
Personnel.
Metrics used to measure efficiency and effectiveness of operation
and maintenance program

Maintenance Engineering 9
 Introduction
Metrics used to measure efficiency and effectiveness of operation and
maintenance program

Maintenance Engineering 10
 Operation and Maintenance Potential, Energy Savings

Energy saving is an important issue for the industrial sectors which is a crucial
factor in energy cost, waste reduction and environmental management.

Maintenance operations are fundamental in granting machineries and processes

energy saving, given the capability of optimizing them using a predictive model.

To ensure that the plant achieved the desired performance it needs a track
performance on maintenance operations and maintenance results.

Deterioration of manufacturing systems’ condition, and hence its capability, begins

to take place as soon as the system is commissioned.

Maintenance Engineering 11
 O &M energy saving Count…

In addition to normal wear and deterioration, other failures may occur
especially when the equipment are pushed beyond their design limits or
due to operational errors.

As a result, equipment downtime, quality problems, energy losses, safety

hazards or environmental pollution become the obvious outcomes.

All these outcomes have the potential to impact negatively the operating
cost, profitability, customers’ demand satisfaction, and productivity
among other important performance requirements.
Maintenance Engineering 12
 O &M energy saving Count…

It has been estimated that O&M programs targeting energy efficiency can save
energy cost without a significant capital investment
From machines in industries, these savings can represent thousands to
hundreds of thousands of money each year, and many can be achieved with
minimal cash outlays.
, Beyond the potential for significant cost and energy/resource savings an O&M
program operating at its peak “operational efficiency” has other important
implications.

Maintenance Engineering 13
 O &M energy saving Count…

A well-functioning O&M program is a safe O&M program.

Equipment is maintained properly, mitigating any potential hazard arising

from deferred maintenance.

Properly performed O&M helps ensure that the design life expectancy of
equipment can be achieved, and in some cases, exceeded.

Conversely, the costs associated with early equipment failure are usually not
budgeted for, and often come at the expense of other planned activities

Maintenance Engineering 14
 O &M energy saving Count…

An effective O&M program aids in a facility’s compliance policies such as the Clean
Air Act and the Clean Water Act.

A well functioning O&M program is not always reactive (answering complaints);

rather, it is proactive in its response, and corrects situations before they become
problems.

This model minimizes unplanned machine failures or downtime while allowing

more time for scheduled maintenance

Maintenance Engineering 15
 O &M energy saving Count…

Maintenance Engineering 16
 Ten Steps for Operational Efficiency

It is impossible to change the efficiency without changing the safety of the
operation and the resultant life of the equipment, which in turn affects
maintenance cost

This fouling will result in an increase in stack temperature, thus decreasing the
efficiency of the equipment.

 A metal failure will also change the life of the equipment, since fouling
material will allow corrosion to occur, leading to increased maintenance cost
and decreased equipment reliability and safety.

Maintenance Engineering 17
 Ten Steps for Operational Efficiency

1. Keep the equipment room clean and clear of all unnecessary

items.
The equipment room should not be considered an all-purpose storage area.
The burner requires proper air circulation in order to prevent incomplete
fuel combustion.
Use equipment operating log sheets, maintenance records, and the
production of carbon monoxide.

The boiler room is for the boiler!

Maintenance Engineering 18
 Ten Steps for Operational Efficiency

2. Ensure that all personnel who operate or maintain the equipment

room are properly trained on all equipment, controls, safety
devices, and up-to-date operating procedures.

3. Before start-up, ensure that the equipment room is free of all

potentially dangerous situations, like flammable materials,
mechanical, or physical damage to the equipment or related
equipment. Clear intakes and exhaust vents; check for
deterioration and possible leaks.
Maintenance Engineering 19
 Ten Steps for Operational Efficiency

4. Ensure a thorough inspection by a properly qualified inspector.

5. After any extensive repair or new installation of equipment, make sure a qualified
equipment inspector re-inspects the entire system.

6. Monitor all new equipment closely until safety and efficiency are demonstrated.

Maintenance Engineering 20
 Ten Steps for Operational Efficiency

7. Use equipment operating log sheets, maintenance records, and

manufacturer’s recommendations to establish a preventive maintenance
schedule based on operating conditions, past maintenance, repair, and
replacement that were performed on the equipment.

8. Establish a checklist for proper startup and shutdown of equipment and all
related equipment according to manufacturer’s recommendations.

Maintenance Engineering 21
 Ten Steps for Operational Efficiency

9. Observe equipment extensively before allowing an

automating operation system to be used with minimal

supervision.

10. Establish a periodic preventive maintenance and safety

program that follows manufacturer’s recommendations

Maintenance Engineering 22
Ten Steps for Operational Efficiency

Maintenance Engineering 23