Chapter 2

Machine Installation and Maintenance
(MaEng4261)
Raya University
Engineering and Technology Collage(ETC)
Department of Manufacturing Engineering
Lecturer of the Course : Haftekiros Y.

Manufacturing Engineering
Email: [email protected]
Chapter – two
2. Maintenance Policies – Preventive Maintenance
2.1 Types Of Maintenance Systems
1. Preventive Maintenance (PM)
 It is a set of activities that are performed on plant equipment,

machinery, and systems before the occurrence of a failure
 That is, in order to protect them and to prevent or eliminate any

degradation in their operating conditions.
 The maintenance carried out at predetermined intervals or according to

prescribed criteria, and
 Intended to reduce the probability of failure or the degradation of the

functioning and the effects limited.
Advantages and Dis-Advantages of Preventive
Maintenance (PM)
Advantages Dis Advantages

 Less risk factor More money upfront-
 Follows a schedule Over maintenance
 Longer equipment/building More workers(labors)
 Less energy wasting
 Less disruptions
Elements of Preventive Maintenance
There are seven major elements of preventive maintenance which a maintenance engineer
must be conversant with and these are listed below
TESTING: There is need to periodically test equipment or machine to determine

whether there is a need for servicing.
SERVICING: It is recommended that equipment be periodically lubricated, cleaned and

charged to keep it in top working condition even without any suspicion for breakdown.
CALIBRATION: This implies the detection and adjustment of any changes in the
accuracy of the parameters of the system under comparison to the established standard
value.
INSPECTION: Periodically, equipment must be inspected to discover whether there
is need for servicing or not by comparing their electrical, mechanical and physical
states to the established standards.
ADJUSTMENT: This refers to making necessary modification to any slip up slip

down components to ensure better performance.
ALIGNMENT: This involves making necessary changes to a device's indicated

variable to ensure better performance.
INSTALLATION: Periodically, install items undergoing wear degradation to keep

the specified tolerance limit.
The Six Principles of Painless Preventive
Maintenance
Principle 1: Clear Division of Responsibilities

Principle 2: Focus on Critical Assets First
Principle 3: Set Standards and Track Exceptions
Principle 4: Invite Your Vendors In
Principle 5: Don't Tie Your Field Teams to a Desk
Principle 6: Keep it Simple

Preventive Maintenance (PM)
Researchers subdivided preventive maintenance into different kinds according to the

nature of its activities:
1. Routine maintenance
 Maintenance activities that are repetitive and periodic in nature Example such as
lubrication, cleaning, and small adjustment.
2. Running maintenance
 Maintenance activities that are carried out while the machine or equipment is running.
 It represent those activities that are performed before the actual preventive
maintenance activities take place.
3. Opportunity maintenance
 Maintenance activities that are performed on a machine when an unplanned

opportunity exists during the period of performing planned maintenance activities
to other machines or facilities.
4. 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.
5. Shutdown preventive maintenance
 which is a set of preventive maintenance activities that are carried out when the
production line is in total stoppage situation.
2. Corrective Maintenance (CM)
 In this type, actions such as repair, replacement, or restore will be
carried out after the occurrence of a failure in order to eliminate the
source of this failure or reduce the frequency of its occurrence.
Note : there are three type of corrective maintenance
1. Remedial maintenance
2. Deferred maintenance
3. Shutdown corrective maintenance

Type of Corrective Maintenance (CM)
1. Remedial maintenance
 It is a set of activities that performed to eliminate the source of failure without

interrupting the continuity of the production process.
2. Deferred maintenance
 It is set of corrective maintenance activities that are not immediately initiated after
the occurrence of a failure
 It is some what delayed in such a way that will not affect the production process.
3. Shutdown corrective maintenance
 It is a set of corrective maintenance activities that are performed when the production
line is in total stoppage situation.
The main objectives of corrective maintenance
The way to perform corrective maintenance activities is by conducting four important

steps:
 Fault detection
 Fault isolation
 Fault elimination. and
 Verification of fault elimination.
Note: In the fault elimination step several actions could be taken such as adjusting,
aligning, calibrating, reworking, removing, replacing or renovation.
Corrective maintenance has several prerequisites in order to be carried out
effectively:
1. Accurate identification of incipient problems.
2. Effective planning which depends on the skills of the planners, and the required
labour skills, specific tools, parts and equipment.
3. Proper repair procedures.
4. Adequate time to repair.
5. Verification of repair.
3. Improvement Maintenance (IM)
It aims at reducing or eliminating entirely the need for maintenance.
This type of maintenance is subdivided into three types as follows:
1. Design-out maintenance
2. Engineering services
3. Shutdown improvement maintenance

1. Design-out maintenance
 It simplify maintenance tasks, or raise machine performance from the maintenance point of
view by redesigning those machines and facilities
2. Engineering services
which includes: Construction and construction modification,
 Removal and installation
 Rearrangement of facilities.
3. Shutdown improvement maintenance
 which is a set of improvement maintenance activities that are performed while the
production line is in a complete stoppage situation.
4. Predictive Maintenance (PDM)
 Predictive maintenance is a set of activities that detect changes in the physical

condition of equipment.
 It is classified into two kinds according to the methods of detecting the signs of
failure:
1. Condition-based predictive maintenance
2. Statistical-based predictive maintenance

1. Condition-based predictive maintenance
 It depends on continuous or periodic condition monitoring equipment to

detect the signs of failure.
2. Statistical-based predictive maintenance
 It depends on statistical data from the particular recording of the stoppages

of the in-plant items and components in order to develop models for
predicting failures.
2.2 Total productive maintenance (TPM)
 TPM also focuses on the total Participation of individuals from top

management to shop floor (lower employees).
 It focuses on keeping all equipment in top working condition to avoid

breakdowns and delays in manufacturing processes.
 It is a system of maintaining and improving the integrity of production and

quality systems.
 It compile with all the machines, equipment, processes, and employees that add
business value to an organization.
The Main objectives of TPM
 To increase the productivity of plant and equipment with a modest investment
in maintenance.
 To Enhance the volume of the production, employee morale and job satisfaction
 To increase the Overall Equipment Effectiveness (OEE) of plant equipment.
 OEE has three factors which are multiplied to give one measure called
Overall Equipment Effectiveness
 OEE=Performance x Availability x Quality

The Eight pillars of TPM
1. Autonomous Maintenance
2. Focused Improvement
3. Planned Maintenance
4. Quality management
5. Early/equipment management
6. Education and Training
7. Safety Health Environment
8. Administrative & office TPM

Basic steps for implementation of TPM
- Initial evaluation of TPM level,
- Introductory Education and Advertising (IEA) for TPM,
- Formation of TPM committee,
- Development of master plan for TPM implementation,
- Stage by stage training to the employees and stakeholders
- Implementation preparation process, and
- Establishing the TPM policies and goals and development of a road map for TPM
implementation.
Assignment 1(10%)
1. Reliability centered maintenance (RCM)
2. Run to Failure Maintenance (RTF)
2.3 Spares Provisioning (Planning Of The Spares Stock)
 Spares provisioning plays an important role in achieving the desired plant

availability at an optimum cost.
 Industries nowadays are going for capital intensive, mass production oriented,
and highly improved technology. They cannot afford to have downtime for such
plant and machinery.
 Non-availability of spare parts, as and when required for repairs, may contribute to
as much as 50% of the total down time. In addition, the cost of spare parts is more
than 50% of the total maintenance cost in the industry. While maintenance
department complains of the non-availability of the spare parts to meet their
requirement, finance department faces the problem of
increasing locked up capital in spare parts inventory.
 This is why spare parts management is essential in any organization.
There is a need for systematic actions while managing spare parts as given below:
a. Identification of spare parts
b. Forecasting of spare parts requirement
c. Inventory analyses
d. Formulation of selective control policies for various categories
e. Development of inventory control systems
f. Stocking policies for capital & insurance spares
g. Stocking policies for rotable spares or sub- assemblies
h. Replacement policies for spare parts
i. Spare parts inspection
j. Indigenization of spares
k. Reconditioning of spare parts
l. Establishment of spare parts bank
m. Computerization of spare parts management.
Arrangement of spare parts in warehouse
2.4 Decision making and basic probability concepts
2.4.1 Decision making

• Decision-making is an essential skill for operational team leaders.
• Applying a systematic method to solve problems is critical to team performance and
the safety of operations.
• Team members share the responsibility for solving problems by contributing timely
and valuable information to the team leader.
• Decision making is the study of identifying and choosing alternatives based on the
values and preferences of the decision maker.
• Making a decision implies that there are alternative choices to be considered, and in
such a case we want not only to identify as many of these alternatives as possible but
to choose the one that best fits with our goals, objectives, desires, values, and so on..
a general decision making process can be divided into the following steps:
Step1. Define the problem
• This process must, as a minimum, identify root causes, limiting assumptions, system and
organizational boundaries and interfaces, and any stakeholder issues.
Step2. Determine requirements
• Requirements are conditions that any acceptable solution to the problem must meet.
• Requirements spell out what the solution to the problem must do.
Step3. Establish goals
• Goals are broad statements of intent and desirable programmatic values.
Step4. Identify alternatives
• Alternatives offer different approaches for changing the initial condition into the desired
condition.
Step5. Define criteria
• Decision criteria, which will discriminate among alternatives, must be based on the goals.
The following actions have been observed in effective decision-making.
• Gather information before making a decision.
• Cross check information sources for agreement.
• Identify alternatives/contingencies so that possible solutions may be explored.
• Discuss consequences of decisions in an effort to enhance the decision-
making process.
• Provide the rationale for decisions.
Assignment 1(10%)
1. Basic probability concepts
2. Network analysis for planning and control of
maintenance work

Chapter 2

Uploaded by

Copyright:

Available Formats

Chapter 2

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Chapter 2

Uploaded by

Copyright:

Available Formats

Machine Installation and Maintenance

Lecturer of the Course : Haftekiros Y.

 It is a set of activities that are performed on plant equipment,

 That is, in order to protect them and to prevent or eliminate any

 The maintenance carried out at predetermined intervals or according to

 Intended to reduce the probability of failure or the degradation of the

Advantages Dis Advantages

 Longer equipment/building More workers(labors)

 Less energy wasting

TESTING: There is need to periodically test equipment or machine to determine

SERVICING: It is recommended that equipment be periodically lubricated, cleaned and

ADJUSTMENT: This refers to making necessary modification to any slip up slip

ALIGNMENT: This involves making necessary changes to a device's indicated

INSTALLATION: Periodically, install items undergoing wear degradation to keep

Principle 1: Clear Division of Responsibilities

Principle 3: Set Standards and Track Exceptions

Principle 4: Invite Your Vendors In

Principle 5: Don't Tie Your Field Teams to a Desk

Principle 6: Keep it Simple

Researchers subdivided preventive maintenance into different kinds according to the

 Maintenance activities that are performed on a machine when an unplanned

5. Shutdown preventive maintenance

Note : there are three type of corrective maintenance

3. Shutdown corrective maintenance

 It is a set of activities that performed to eliminate the source of failure without

The way to perform corrective maintenance activities is by conducting four important

 Fault elimination. and

 Verification of fault elimination.

1. Accurate identification of incipient problems.

3. Proper repair procedures.

4. Adequate time to repair.

It aims at reducing or eliminating entirely the need for maintenance.

This type of maintenance is subdivided into three types as follows:

3. Shutdown improvement maintenance

which includes: Construction and construction modification,

 Removal and installation

3. Shutdown improvement maintenance

 Predictive maintenance is a set of activities that detect changes in the physical

1. Condition-based predictive maintenance

2. Statistical-based predictive maintenance

 It depends on continuous or periodic condition monitoring equipment to

2. Statistical-based predictive maintenance

 It depends on statistical data from the particular recording of the stoppages

 TPM also focuses on the total Participation of individuals from top

 It focuses on keeping all equipment in top working condition to avoid

 It is a system of maintaining and improving the integrity of production and

 To increase the Overall Equipment Effectiveness (OEE) of plant equipment.

 OEE=Performance x Availability x Quality

6. Education and Training

7. Safety Health Environment

8. Administrative & office TPM

- Introductory Education and Advertising (IEA) for TPM,

- Formation of TPM committee,

- Development of master plan for TPM implementation,

- Stage by stage training to the employees and stakeholders

- Implementation preparation process, and

 Spares provisioning plays an important role in achieving the desired plant

2.4.1 Decision making

You might also like