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Topic1IntroductiontoMaintenanceManagement PDF
Topic1IntroductiontoMaintenanceManagement PDF
Introduction to
Maintenance
Management
LEARNING OUTCOMES
By the end of this topic, you should be able to:
1.
2.
3.
4.
5.
6.
X INTRODUCTION
TOPIC 1
What comes to mind when you hear the term maintenance management? Do
you know that a large portion of an organisations revenue goes to maintenance
costs? Studies have shown that maintenance costs may vary between 15% and
60% of the total cost of production, depending on the industry.
However, in most organisations, maintenance is not a top priority and in most
cases, the maintenance division bears the brunt when something goes wrong in
the organisation such as loss of production and revenue. It is typical to find that
even costs which are not related to maintenance would also be accounted for
as maintenance cost. For example, the cost of adding new equipment and
improvement to the existing equipment is considered maintenance cost when in
actual fact it is a capital investment.
This is why we need to know the meaning of maintenance management and its
expectations and objectives. In this topic, we will learn about the importance of
maintenance management and its three key components (maintainability,
reliability and availability). Next, we will look at the three elements of effective
maintenance management (reducing downtime, extending operation time and
optimum utilisation). Lastly, we will discuss the strategies for a sustainable
maintenance management programme (maintenance management policy,
management commitment and managing maintenance as a business).
1.1
TOPIC 1
W 3
One thing to remember is that maintenance management is like having the mind
of a mechanic but with the ability of a manager. Imagine your car overheats and
breaks down during a family outing. At that point, you are willing to pay any
amount to a mechanic that comes by to get the car fixed in order to get your
family home safely. However, if you have been managing the maintenance of
your car regularly, you would have prevented the failure within a fraction of the
cost. However, here is something for you to remember; even new cars can break
down (see Figure 1.1)!
Figure 1.1: Even a new car can break down if you do not manage the maintenance of your
car regularly
1.2
Can you name the maintenance managers in your organisation? What can
you say about them? Most often, the word maintenance carries a negative
connotation in any organisation. This is evidently seen in the level of importance
and priority given to any maintenance personnel in an organisation. They are
needed and important only when problems arise, and are usually blamed for
poor maintenance. However, when things go right, they are not praised or
rewarded as it is considered to be their job anyway. Hence, many people do
not pursue maintenance management as a career of their choice.
TOPIC 1
(b)
(c)
1.3
TOPIC 1
W 5
The third generation or the last two decades has placed a much higher
expectation on maintenance. It has seven characteristics as listed in Figure 1.2.
Figure 1.3: In the early days, a car was considered a luxury item
Source: http://www.harrisoncars.co.uk/heritage-images/OldPics026RWS809rear.jpg
TOPIC 1
At that time the car is expected to break down and the maintenance is always fix
when broken. However, in the next generation, having a car became essential
and one with air-conditioning and other features such as radio and safety belt for
the front passenger is an added feature. It is also expected to consume less fuel
with a low maintenance cost.
Subsequently, the expectations of owning a car are very high. It has to have an
appealing look with an aesthetic finish, an exclusive interior plus accessories
such as leather seats and other digital gadgets. In addition, it must come with
state of the art safety and security features such as front and rear sensors, safety
belts for all passengers, wireless remote and many more. Figure 1.4 shows
examples of these luxury cars.
The biggest expectation is that it must be reliable with less fuel consumption,
environmentally friendly and with higher power output. Most importantly, it
must be robust and if possible require no maintenance. But in reality, these cars
are yet to exist.
TOPIC 1
1.4
W 7
TOPIC 1
1.5
Reliability
Availability
Description
x
How do these three key components link with maintenance and maintenance
management? Let us look at these important notes.
Maintenance is about performing all actions in keeping a balance between
maintainability, reliability and availability.
TOPIC 1
1.6
W 9
(b)
(c)
1.7
10 X
1.7.1
TOPIC 1
1.7.2
Management Commitment
ACTIVITY 1.1
Can we measure the commitment given by all the employees? How
do we make sure that they are dedicated and consistent all the time?
1.7.3
Recent surveys have shown that approximately 1/3 of the actual reported
maintenance cost is either non-maintenance cost or in some cases wasted cost
due to improper maintenance management. This ineffectiveness not only impacts
the production and operation cost but also affects the quality of the production,
hence resulting in the industry unable to get a fair share in the global market.
Evidently, there is a growing need for every industry to consider maintenance as
a business entity than merely being a cost centre. The shift in paradigm will lead
to managing maintenance as a business.
TOPIC 1
W 11
SELF-CHECK 1.1
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2.
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You have just learned the basic concepts of maintenance management. Now,
what can you conclude about maintenance management? You can say that:
12 X
TOPIC 1
Lastly, you learnt that there are three strategies for sustainable maintenance
management programme: maintenance management policy, management
commitment and managing maintenance as a business.
Availability
Maintenance management
Maintainability
Reliability