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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. Reasons for Maintenance Maintenance serves to protect the owners’ real estate investment in a number of ways Physical Integrity To keep the assets in good working order so as to minimize disruptions and downtimes. Risk Management To keep the assets in a state of good repair for the owners’ health and safety. Aesthetic Preservation To keep the assets from deteriorating in appearance and becoming unsightly. Responsible Stewardship To ensure that the assets achieve their full potential service life. Duty of Care To satisfy a legislated duty that is owed to owners, occupants and guest on the property. Duty to Mitigate To prevent unnecessary damage to assets that may result in their premature failure. Types Of Maintenance
Breakdown maintenance Preventive maintenance Predictive maintenance Corrective maintenance Break Down Maintenance It means that people waits until equipment fails and repair it. Such a thing could be used when the equipment failure does not significantly affect the operation or production or generate any significant loss other than repair cost. Preventive maintenance
It is a daily maintenance ( cleaning, inspection, oiling and re-tightening ),
design to retain the healthy condition of equipment and prevent failure through the prevention of deterioration, periodic inspection or equipment condition diagnosis, to measure deterioration. It is further divided into periodic maintenance and predictive maintenance. Just like human life is extended by preventive medicine, the equipment service life can be prolonged by doing preventive maintenance. Predictive maintenance This is a method in which the service life of important part is predicted based on inspection or diagnosis, in order to use the parts to the limit of their service life. Compared to periodic maintenance, predictive maintenance is condition based maintenance. It manages trend values, by measuring and analysing data about deterioration. Condition Monitoring Condition monitoring is the process of determining the condition of machinery while in operation. The key to a successful condition monitoring programme includes: 1. Knowing what to listen for 2. How to interpret it 3. When to put this knowledge to use Successfully using this programme enables the repair of problem components prior to failure. Condition monitoring not only helps plant personnel reduce the possibility of catastrophic failure, but also allows them to order parts in advance, schedule manpower, and plan other repairs during the downtime. Corrective maintenance It improves equipment and its components so that preventive maintenance can be carried out reliably. Equipment with design weakness must be redesigned to improve reliability or improving maintainability Advantages And Disadvantages Break Down Maintenance Advantages Disadvantages
Lower start up cost Unpredictability
Limited personnel requirement Equipment not maximised
Reduced maintenance costs Indirect costs
Potentially increased margins
Preventive Maintenance
Advantages Disadvantages Over all very cost effective Catastrophic failure still a risk Flexibility can allow for adjustment of Labour Intensive schedule to accommodate other work Increased equipment life Performance of maintenance based on schedule not required Saved energy cost resulting from Risk of damage when conducting equipment running from pick efficiency unneeded maintenance Reduced equipment or process failure Saving not readily visible without a base line Over all saving between 12% to 18% Predictive Maintenance
Advantages Disadvantages Increased component operational Increased investment of diagnostic life/availability equipment Allows for pre-emptive corrective Increased staff training for analysing action data Decreased part and labour cost Saving not readily visible without a baseline/history Improved safety and environment Energy savings Over all saving between 8% to 12% over preventive maintenance Condition Monitoring
Advantages Disadvantages Extend bearing service life Monitoring equipment costs Maximise machine productivity Operational costs (running the program) Minimise unscheduled downtime Skilled personnel needed Safely extend overhaul intervals Strong management commitment needed. Improve repair time A significant run-in time to collect machine histories and trends is usually needed. Increased machine life Improve product quality Reduce product cost Enhance product safety Corrective Maintenance
Advantages Disadvantages Lower short-term costs Increased long-term costs due to unplanned equipment downtime. Requires less staff since less work is Possible secondary equipment or being done process damage. Prone to neglect of assets 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 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.
