CHAPTER 6

MAINTENANCE
MANAGEMENT
Introduction to Maintenance
The importance..
 Maintenance and reliability(ability to function as
designed at specified time range) is important
 Maintenance and product quality
 Maintenance and productivity
 Maintenance and safety

 Failure cause disruption (disturbance), waste,

accident, inconvenience and expensive.
 Operators less able to do repairs themselves
 Machine and product failure can have effect on
company’s operation and profitability
 Idle workers, facility
 Losses due to breakdown
 FAILURE

Failure – inability to produce work in

appropriate manner

 Equipment / machine failure on production

floor
– worn out bearing, pump, pressure leaks, broken
shaft, overheated machine etc.
 Equipment failure in office
– failure of power supply, air-conditioned system,
computer network, photocopy machine
 Vehicle failure
– brake, transmission, engine, cooling system
 MAINTENANCE IN SERVICE INDUSTRY

i. Hospital
ii. Restaurants
iii. Transport companies
iv. Banks
v. Hotels and resorts
vi. Shopping malls / retail
vii. Gas station
 MAINTENANCE IN MANUFACTURING
COMPANIES

i. Electronic
ii. Automotive
iii. Petrochemicals
iv. Refinery (processing plant)
v. Furniture
vi. Ceramics
vii. Food and beverages
 MAINTENANCE

i. All actions necessary for retaining(keep in an existing

state) an item, or restoring to it, a serviceable condition,
 servicing, repair, modification, overhaul, inspection and
condition verification(check for correctness)

ii. Increase availability (present and ready for use) of a

system

iii. Keep system’s equipment in working order

iv. Consider work orders, work scheduling, repair parts

inventory etc.
 Question?

 Why do we need maintenance?

 What are the costs of doing maintenance?
 What are the costs of not doing maintenance?
 What are the benefits of maintenance?
 How can maintenance increase profitability of
company?
 PURPOSE OF MAINTENANCE

a) Attempt to maximize performance of production

equipment efficiently and regularly
b) Prevent breakdown or failures
c) Minimize production loss from failures
d) Increase reliability of the operating systems
 PRINCIPLE OBJECTIVES IN MAINTENANCE

i. To achieve product quality and customer

satisfaction through adjusted and serviced
equipment

ii. Maximize useful life of equipment

iii. Keep equipment safe and prevent safety hazards

iv. Minimize frequency and severity of interruptions

v. Maximize production capacity – through high

utilization of facility
 TYPES OF MAINTENANCE

Maintenance may be classified into four categories:

 (some authors prefer three categories- scheduled and
preventive maintenances are merged)

a. Corrective or Breakdown maintenance

b. Scheduled maintenance
c. Preventive maintenance
d. Predictive (Condition-based) maintenance
 Corrective or Breakdown
Maintenance
Types of Maintenance
1. Corrective/Breakdown
2. Scheduled
3. Preventive
4. Predictive (Condition-based)

 Corrective/Breakdown maintenance means that

repairs are made
– after the equipment is failed and can not perform its
normal function anymore

 Quite acceptable in small factories where:

– Down times are non-critical and repair costs are less
than other type of maintenance
– Financial justification for scheduling are not felt
 Types of Maintenance
Scheduled Maintenance 1. Corrective/Breakdown
2. Scheduled
3. Preventive
4. Predictive (Condition-based)

i. Scheduled maintenance is a stitch-in-time (periodic)

procedure and includes
 inspection
 lubrication
 repair and overhaul of equipments

ii. If neglected can result in breakdown

iii. Generally followed for:

 overhauling of machines
 changing of heavy equipment oils
 cleaning of water and other tanks etc.
 Types of Maintenance
Preventive Maintenance (PM) 1. Corrective/Breakdown
2. Scheduled
3. Preventive
4. Predictive (Condition-based)

 Principle – “Prevention is better than cure”

 Procedure - Stitch-in-time
 It
– Locates weak spots of machinery and equipment before they
occur or before they develop into major defects.

– Provides them periodic/scheduled inspections and minor

repairs to reduce the danger of unanticipated breakdowns
 Types of Maintenance
Predictive Maintenance 1. Corrective/Breakdown
2. Scheduled
3. Preventive
4. Predictive (Condition-based)

i. In predictive maintenance, machinery conditions are

periodically monitored
 this enables the maintenance crews to take suitable actions,
such as machine adjustment, repair or overhaul

ii. It makes use of human sense and other sensitive

instruments, such as:
 audio gauge,
 vibration analyzer,
 amplitude meter,
 pressure,
 temperature
 resistance strain gauges etc.
 Predictive Maintenance

iii. Unusual sounds coming out of a rotating equipment

predicts a trouble

iv. An excessively hot electric cable predicts a trouble

v. Simple hand touch can point out many unusual

equipment conditions and thus predicts a trouble
Examples:
 Scenario: An individual bought a incandescent light bulb. The
manufacturing company mentioned that the life span of the
bulb is 3 years. .
1. Just before the 3 years, the individual decided to replace
the bulb with a new one.
preventive maintenance

2. On the other hand, the individual has the opportunity to observe the bulb
operation daily. After two years, the bulb starts flickering. The individual
predicts at that time that the bulb is going to fail very soon and decides to
change it for a new one.
predictive maintenance.
3. The individual ignores the flickering bulb and only goes out to buy
another replacement light bulb when the current one fails.
corrective maintenance.
RELIABILITY
DEFINITION OF RELIABILITY

“Probability that a system or product will

perform in a satisfactory manner for a given
period of time when used under specified
operating condition”
 RELIABILITY

Specified
Satisfactory
Probability Specified time operating
performance
conditions
numerical criteria used to predict Expect a
representation established probability of an system to
- number of which describe item surviving function-
times that an what is without failure • environment
event occurs considered to for a al factors,
(success) be satisfactory designated humidity,
divided by system period of time vibration,
total number operation shock,
trials temperature
cycle,
operational
profile, etc.
 LIFE CYCLE CURVE

i. Typical life history curve for infinite no. of items –

‘bathtub curve’

ii. Comparison of failure rate with time

iii. 3 distinct phase

– debugging
– chance failure
– wear-out phase
 LIFE CYCLE CURVE

Hazard Debugging Chance Failure Wear Out

elements Phase Phase Phase
Failure Rate (λ)

Time (t)
Debugging (Infant mortality) Phase

Debugging Chance Failure Wear Out

Failure Rate (λ)

Phase Phase Phase

Time (t)

 When first introduced

 rapid decrease in failure rate
 Weibull distribution with shape parameter  < 1 (failure
rate decreases over time) is used to describe the
occurrences of failure
 Usually covered by warranty period
 Chance Failure Phase

Debugging Chance Failure Wear Out

Failure Rate (λ)

Phase Phase Phase

Time (t)

 During product "useful life"

 Constant failure rate – failure occur in random
manner
 Exponential and also Weibull with  =1 can be used
to describe this phase
 Wear-out phase
Debugging Chance Failure Wear Out

Failure Rate (λ)

Phase Phase Phase

Time (t)

 Product exceeds its design lifetime

 Sharp rise in failure rate – fatigue, corrosion (old age)
 Normal distribution is one that best describes this phase
 Also can use Weibull with shape parameter  > 1
(failure rate increases with time)
 MAINTAINABILITY
i. Related to the ease, accuracy, safety and economy
in the performance of maintenance actions

ii. Ability of an item to be maintained

iii. Maintainability is a design parameter, maintenance

is a result of design
 MAINTAINABILITY

iii. Frequency of maintenance for a given time is highly

dependent on the reliability of that item

iv. Reliability HIGH ,frequency of maintenance LOW

v. Unreliable system require extensive maintenance

End of Chapter 6…