Lecture No.

1 Course: Maintenance Engineering and Management

Module I
Importance and Objectives of maintenance
Types of maintenance, Maintenance systems
Planned and unplanned maintenance
Subject Teacher:
Dr. Trupti Ranjan Mahapatra
Associate Professor
7978035018
[email protected]

Department of Production Engineering

VSSUT, Burla
Lecture No. 1 Course: Maintenance Engineering and Management
COURSE OUTCOMES: At the end of this course, students will demonstrate the ability to
1.   Understand basic objectives of maintenance and enumerate their various types.
2. Explain the process of establishing a maintenance plan and the characteristics of
diverse items to be maintained.
3. Describe maintenance organizational structure and recognise the documentation
and record keeping of maintenance operations.
4. Undertake spare planning and scheduling plant shut downs.
5.  Evaluate maintenance performance and explain basic systems of TPM.

TEXT BOOK(S):
1.   Industrial Maintenance Management- S. K. SRIVASTAVA, S.Chand & CompanyLtd.
2. Maintenance Engineering and Management-R.C.Mishra, K.Pathak, PHI Learning
Pvt. Ltd.
 
REFERENCE BOOK(S):
1.   Maintenance Planning and Control- A. Kelly, East WestPress.
1.   Handbook of Maintenance Management- Levitt Joel, Industrial Press.
1.   Introduction to Maintenance Engineering: Modelling, Optimization and Management by D. N.
Prabhakar Murthy, Mohamed Ben-Daya, and Uday Kumar, Wiely
1.   Plant Equipment & Maintenance Engineering Handbook by Duncan Richardson, Mc Graw Hill
Education.
Lecture No. 1 Course: Maintenance Engineering and Management
Maintenance: the process of preserving/protecting

Maintenance is a routine and recurring activity of keeping a particular machine or facility at its
normal operating condition so that it can deliver its expected performance or service without
causing any loss of time on account of accidental damage or breakdown”.

How it Repairs
Repair is the work completed to fix damage or deterioration of a property

 Maintenance is defined as work completed to prevent deterioration to a property, for

example mowing the lawns.
 Any activity—such as tests, measurements, replacements, adjustments, and repairs—
intended to retain or restore a functional unit in or to a specified state in which the unit can
perform its required functions.
 All action taken to retain equipment/material in a serviceable condition or to restore it to
serviceability. It includes inspections, testing, servicing, classification as to serviceability,
repair, rebuilding, and reclamation.
 All supply and repair action taken to keep a force in condition to carry out its mission.
 The routine recurring work required to keep a facility (plant, building, structure, ground
facility, utility system, or other real property) in such condition that it may be continuously
used, at its original or designed capacity and efficiency for its intended purpose
Lecture No. 1 Course: Maintenance Engineering and Management
Maintenance may be part of a planned programme or may have to be carried out at short
notice after a breakdown.

Maintenance Engineering is the discipline that deals with applying engineering concepts for
the optimization of equipment, procedures, and resources to achieve better availability,
reliability, and functioning of equipment.
 The development of mechanization and automation of production systems and associated
equipment,
 Maintenance function also involves looking after the safety aspects of certain equipment
where the failure of component may cause a major accident.
 Assure optimization of the Maintenance Organization structure
 Analysis of repetitive equipment failures and Forecasting of spare parts
 Estimation of maintenance costs and evaluation of alternatives
 Assessing the needs for equipment replacements and establish replacement
programs
 Application of scheduling and project management principles to replacement
programs
 Assessing required maintenance tools and skills required for efficient
maintenance of equipment and personnel
 Reviewing personnel transfers to and from maintenance organizations
 Assess and report safety hazards associated with maintenance of equipment
Lecture No. 1 Course: Maintenance Engineering and Management
Maintenance Management:

 The management and control of maintenance activities are equally important to

performing maintenance.

 Maintenance management may be described as the function of providing policy guidance

for maintenance activities, in addition to exercising technical and management control of
maintenance programs. Centralized maintenance serves well in small- and medium-sized
enterprises housed in one structure, or service buildings located in an immediate
geographic area.

 A maintenance policy is one of the most important elements of effective maintenance

management. It is essential for continuity of operations and a clear understanding of the
maintenance management program, regardless of the size of a maintenance organization.

 Equipment records play a critical role in effectiveness and efficiency of the maintenance
organization. Job planning is an essential element of the effective maintenance
management.

 Successful maintenance organizations regularly measure their performance through

various means. Management employs various approaches to measure effectiveness of the
maintenance function.
Lecture No. 1 Course: Maintenance Engineering and Management

Importance of maintenance:
 Maintenance is an important factor in quality assurance and in some cases determines the
long-term success of a company.
 Poorly maintained resources can cause instability and partially or completely pause the
production.
 Malfunctioning machines or complete breakdowns can become a costly process.
 Maintenance management is responsible for the smooth and efficient working of the
industrial plant and helps in improving the productivity.
 It also helps to keep the machines/equipment in their optimum operating conditions. Thus
plant maintenance is an important and inevitable service function of an efficient production
system.
 It also helps in maintaining and improving the operational efficiency of the plant facilities
and hence contributes towards revenue by decreasing the operating cost and improving the
quality and quantity of the product being manufactured.
 Absence of plant maintenance may lead to frequent machine breakdown and failure of
certain productive centres/services which in turn would result in stoppages of production
activities, idle man and machine time, dislocation of the subsequent operations, poor quality
of production, failure to meet delivery dates of product supply, industrial accidents
endangering the life of workers/ operators and allied costs etc.
Lecture No. 1 Course: Maintenance Engineering and Management

Importance of maintenance:
 Absence of plant maintenance may lead to frequent machine breakdown and failure of
certain productive centres/services which in turn would result in stoppages of production
activities, idle man and machine time, dislocation of the subsequent operations, poor quality
of production, failure to meet delivery dates of product supply, industrial accidents
endangering the life of workers/ operators and allied costs etc.
 However, the importance of plant maintenance varies with the type of plant and its
production but it plays a prominent role in production management because plant
breakdown creates problems such as:
(i) Loss of production.
(ii) Rescheduling of production.
(iii) Materials wastage (due to sudden stoppage of process damages in
process materials).
(iv) Need for overtimes,
(v) Need for work subcontracting.
(vi) For maximum manpower utilization workers may need alternative work
due to temporary work shortages.
 Hence, the absence of planned maintenance service proves costlier. So it should be provided
in the light of cost benefit analysis. Since plant maintenance is a service function, it should
be provided at the least possible cost but it is very important as discussed above.
Lecture No. 1 Course: Maintenance Engineering and Management

Maintenance Functions: Composite Functions:

1. Replace
2. Repair
3. Overhaul
4. Rebuild
5. Service/Lubricate
6. Inspect/check
7. Test
8. Adjust
9. Align
10. Calibrate
11. Measure
12. Winding
13. Install
Lecture No. 1 Course: Maintenance Engineering and Management
Functions of Maintenance Management:
(1) To develop maintenance policies, procedures & standards for plant maintenance system.
(2) To schedule the maintenance work after due consultation with the production
departments.
(3) To carry out repairs and rectify or overhaul planned equipment/facilities for achieving the
required level of availability and optimum operational efficiency.
(4) To ensure scheduled inspection, lubrication oil checking, and adjustment of plant
machinery and equipment.
(5) To document and maintain record of each maintenance activity (i.e., repairs, replacement,
overhauls, modifications and lubrication etc.).
(6) To maintain and carry out repairs of buildings, utilities, material handling equipment’s and
other service facilities such as electrical installations, sewers, central stores and roadways etc.
(7) To carry out and facilitate periodic inspections of equipment and facilities to know their
conditions related to their failure and stoppage of production.
(8) To prepare inventory list of spare parts and materials required for maintenance.
(9) To ensure cost effective maintenance.
(10) To forecast the maintenance expenditure and prepare a budget and to ensure that
maintenance expenditure is as per planned budget.
Lecture No. 1 Course: Maintenance Engineering and Management

Functions of Maintenance Management:

(11) To recruit and train personnel to prepare the workforce for effective and efficient plant
maintenance.
(12) To implement safety standards as required for the use of specific equipment or certain
categories of equipment such as boilers, overhead cranes and chemical plants etc.
(13) To develop management information systems, to provide information to top
management regarding the maintenance activities.
(14) To monitor the equipment condition at regular intervals.
(15) To ensure proper inventory control of spare parts and other materials required.

In terms of plants operations the functions of maintenance are:

(a) The plant must be available as and when required.

(b) The plant must not breakdown during actual operation state.
(c) The plant must operate in an efficient manner at required level of plant operation.
(d) The down time must not interfere with production runs.
(e) The down time due to breakdown should be a minimum.
Lecture No. 1 Course: Maintenance Engineering and Management
Objectives of maintenance
The purpose of maintenance management is to optimize the performance of productive
facilities of an organization by ensuring that these facilities function regularly and efficiently.
This can be achieved by preventing the failures or breakdowns if any, as far as possible and by
minimizing the production loss due to failures.
(1) Minimizing the loss of productive time because of equipment failure to maximize the
availability of plant, equipment and machinery for productive utilization through planned
maintenance.
(2) To extend the useful life of the plant, machinery and other facilities by minimizing their wear
and tear.
(3) Minimizing the loss due to production stoppages.
(4) To ensure operational readiness of all equipment’s needed for emergency purposes at all times
such as fire-fighting equipment.
(5) Efficient use of maintenance equipment’s and personnel.
(6) To ensure safety of personnel through regular inspection and maintenance of facilities such as
boilers, compressors and material handling equipment etc.
(7) To maximize efficiency and economy in production through optimum utilization of available
facilities.
(8) To improve the quality of products and to improve the productivity of the plant.
(9) To minimize the total maintenance cost which may consist of cost of repairs, cost of preventive
maintenance and inventory costs associated with spare parts/materials required for maintenance.
(10) To improve reliability, availability and maintainability.
Lecture No. 1 Course: Maintenance Engineering and Management
Objectives of maintenance
Lecture No. 1 Course: Maintenance Engineering and Management
Lecture No. 1 Course: Maintenance Engineering and Management
Lecture No. 1 Course: Maintenance Engineering and Management
Types of maintenance

System approach to maintenance

activities
Lecture No. 1 Course: Maintenance Engineering and Management
Developments in
maintenance
Lecture No. 1 Course: Maintenance Engineering and Management

Types of maintenance