Plant Maintenance

6/29/2014
Course outline
 Introduction
 Preventive maintenance
 Scheduled maintenance
Chapter 7  Break-down maintenance
PLANT MAINTENANCE  Total productive

maintenance (TPM)
 Total planned quality
maintenance (TPQM)
‘Well begun is half done.’

Industrial Engineering and Management, BME III/I
Industrial Engineering and Management, BME III/II 2
By: Khem Gyanwali, Thapathali Campus, IOE,TU
1. Introduction 1. Introduction
• Maintenance can be defined as a combination of Objectives of maintenance

actions carried out to replace, repair, service (or 1. Minimum break-down time.
modify) the components or some identifiable 2. Utilization of optimum capacity.
grouping of components in a manufacturing plant
so that it will continue to operate at a specified 3. To keep the life of the equipment.
‘availability’ for a specified time. 4. To ensure highest availability.
• All actions necessary for retaining an item, or 5. To modify the machine tools and other
restoring to it, a serviceable condition, include production facilities.
servicing, repair, modification, overhaul, 6. Economy.
inspection and condition verification. 7. Improve productivity.
• Increase availability of a system. 8. Ensure safety.
• Keep system’s equipment in working order.
Industrial Engineering and Management, BME III/I Industrial Engineering and Management, BME III/I
3 By: Khem Gyanwali, Thapathali Campus, IOE,TU
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1. Introduction 1. Introduction
Problems in Maintenance Problems Exist Due To:

• Lack of management attention to • Failure to develop written objectives and
maintenance policy
• Little participation by accounting in analyzing • Inadequate budgetary control
and reporting costs • Inadequate control procedures for work order,
service requests etc.
• Difficulties in applying quantitative analysis
• Infrequent use of standards
• Difficulties in obtaining time and cost • To control maintenance work
estimates for maintenance works
• Absence of cost reports to aid maintenance
• Difficulties in measuring performance planning and control system
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1. Introduction 2. Preventive maintenance
Types of Maintenance • Principle – “Prevention is better than cure”

Maintenance may be classified into four • Procedure - Stitch-in-time
categories:(some authors prefer three • It consists of routine actions taken in a planned
categories- scheduled and preventive manner to prevent break-down and to ensure
maintenances are merged) operational efficiency to the extent it is economically
• Corrective or Breakdown maintenance and practically possible.
• Scheduled maintenance • It
– locates weak spots of machinery and equipments
• Preventive maintenance
– provides them periodic/scheduled inspections and minor
• Predictive (Condition-based) maintenance repairs to reduce the danger of unanticipated breakdowns
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2. Preventive maintenance 2. Preventive maintenance
Objectives of preventive maintenance Elements of preventive maintenance

1. To minimize the possibility of unanticipated 1. Inspection.
production interruptions by locating or a. External inspection (abnormal sound, vibration, heat,
uncovering any condition which may lead to it. smoke)
2. To make plant equipment and machines always b. Internal inspection (inspection of internal parts)
available and ready for use. 2. Overhauls.
3. To maintain the value of the equipment, 3. Lubrication.
machinery and other service facilities by periodic 4. Planning and scheduling.
inspection, repairs, overhauling etc.
5. Record and analysis.
4. To reduce the work content of maintenance jobs.
6. Training of maintenance staff.
5. To ensure safety of life of employees.
7. Storage of spare parts.
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2. Preventive maintenance 3. Scheduled maintenance
• Advantages: Scheduled maintenance is a stitch-in-time procedure and

–Reduces break down and thereby down time incorporates
–Less odd-time repair and reduces over time of crews – inspection
–Greater safety of workers – lubrication
–Lower maintenance and repair costs – repair and overhaul of equipments
–Less stand-by equipments and spare parts • If neglected can result in breakdown
–Better product quality and fewer reworks and scraps • Generally followed for:
– overhauling of machines
–Increases plant life
– changing of heavy equipment oils
–Increases chances to get production incentive bonus
– cleaning of water and other tanks etc.
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3. Scheduled maintenance 4. Break-down maintenance
Advantages of scheduled maintenance • Corrective or Breakdown maintenance implies that repairs

are made after the equipment is failed and can not perform its
1. It reduces down time during repairs. normal function anymore
• Typical causes of equipment breakdown may be as follows:
2. The break-down is minimized and machines – Failure to replace worn out parts
run at a higher level of efficiency. – Lack of lubrication
– Neglected cooling system
3. Pre-determination of date of commencement – Indifference towards minor faults
of work ensures to plan the work load and – External factors such as too low or too high line voltage, wrong fuel
etc.
distribution of maintenance work force for • Quite justified in small factories where:
balanced attention of all equipment. – Down times are non-critical and repair costs are less than other type
of maintenance
– Financial justification for scheduling are not felt
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4. Break-down maintenance Predictive Maintenance
Disadvantages of corrective or break-down maintenance • In predictive maintenance, machinery conditions are

• Breakdown generally occurs inappropriate times leading periodically monitored and this enables the maintenance
crews to take timely actions, such as machine adjustment,
to poor and hurried maintenance repair or overhaul
• Excessive delay in production & reduces output • It makes use of human sense and other sensitive
• Faster plant deterioration instruments, such as
• Increases chances of accidents and less safety for both –audio gauge, vibration analyzer, amplitude meter, pressure,
temperature and resistance strain gauges etc.
workers and machines
• Unusual sounds coming out of a rotating equipment
• More spoilt materials predicts a trouble
• Direct loss of profit • An excessively hot electric cable predicts a trouble
• Can not be employed for equipments regulated by • Simple hand touch can point out many unusual
statutory provisions e.g. cranes, lift and hoists etc equipment conditions and thus predicts a trouble
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Comparison between break-down and preventive maintenance Comparison between break-down and preventive maintenance
Maintenance costs • It is natural that when cost of preventive

Cost maintenance increases, the cost of breakdown
Total Maintenance Cost decreases.
• But after certain limit, increase in expenditure on
preventive maintenance becomes uneconomical.
PM Cost • For this purpose, these two costs should be plotted in
a graph and cumulative costs of both types of
Breakdown Cost maintenance are superimposed as shown in figure
above from which an optimum point can easily be
determined.
Optimal Maintenance
Commitment
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Maintenance Jobs in Lathe Machine Maintenance Jobs in Lathe Machine
S.N. Parts Maintenance Jobs S.N. Parts Maintenance Jobs

1. Beds and Slides i. The guide ways should be cleaned. 4. Belt and pulley i. Tension and alignment are checked.
ii. Thin lubrication film is put on the guide ways. ii. The burr fallen should be cleaned.
iii. Coolants and burrs are also removed from it. iii. Split lubrication oil should be cleaned.
5. Springs i. Tension should be checked
2. Check/ Tool post i. Nuts are tightened. 6. Gears i. Noise and engagement should be checked.
ii. It is checked for security.
7. Lead screw i. The screw should be cleaned.
iii. It is properly cleaned.
ii. The play in half nut is checked.
iv. New packing may be provided, if tool chatters.
8. Electric motor and i. Earthing, security cover and the pulley on its
starter shaft are checked.
3. Head stock/ Tail i. Surface is cleaned.
ii. Foundation bolts are checked and
stock ii. Tapered holes are cleaned before the centers
tightened, if required.
or tools are attached.
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5. Total Productive Maintenance (TPM) 5. Total Productive Maintenance (TPM)
Total Productive Maintenance (TPM) is a concept which • TPM aims to use equipment at its maximum
aims at ‘Zero Down-Time’. This demands a devoted
participation of all concerned units and individuals at all effectiveness by eliminating waste & loss caused by
levels. failure of the equipment, set up and adjustment,
The concept of maintenance management is an innovation, reduced speed, process defects and reduced yield.
non-traditional approach to plant maintenance and is
complementary with Total Quality Management (TQM), • TPM aims at improving the productivity by improving
Just-In-Time (JIT), Total Employee Improvement (TEI) which its personnel and plant by changing the corporate
are already developed and successfully implemented world
class manufacturing strategies. culture. The operator carries out the daily
maintenance work such as clean up, lubrication,
TPM means tightening and external inspection so that the
- Total employee involvement equipment does not break down.
- Total equipment effectiveness, and
- A total maintenance delivery system
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5. Total Productive Maintenance (TPM) 6. Total Planned Quality Maintenance (TPQM)
A comprehensive definition of TPM involving company TQPM is a comprehensive program which is current in
wide activities includes the following main elements: technology and designed to maximize equipment
1. TPM aims to change corporate culture in order to reliability and plant availability while minimizing
maximize overall effectiveness of production maintenance cost and resources.
systems.
TQPM considers maintenance to be an integrated
2. It establishes a sound system to prevent all kind of function that includes the element like maintenance
losses (zero accidents, zero defects, zero break-
downs) based on actual equipment and workplace. tasks, logistic support, technical documentation,
personnel, work control, management organization and
3. TPM is implemented not only by production related
departments but also by other departments such as administration, maintenance management information
product development, sales, administration etc. flow, measure of effectiveness & maintenance
4. TPM involves every employee, from top engineering.
management to workers, on the shop floor.
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6. Total Planned Quality Maintenance (TPQM)
TPQM addresses both programmatic and technical

concerns of maintenance. It is designed to facilitate the
integration of maintenance element into the quality
process (plan, do, check, act).
TQPM employs reliability centered techniques to define
life cycle maintenance tasks and logistic engineering
techniques to define the resource required.
TPQM permits pre-planning of over 90% of all activities
and is a ‘living process’ designed for continuous
improvement.
Industrial Engineering and Management, BME III/I

25 Industrial Engineering and Management, BME III/II 26

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6/29/2014

PLANT MAINTENANCE  Total productive

‘Well begun is half done.’

• Maintenance can be defined as a combination of Objectives of maintenance

Problems in Maintenance Problems Exist Due To:

1. Introduction 2. Preventive maintenance

Types of Maintenance • Principle – “Prevention is better than cure”

2. Preventive maintenance 2. Preventive maintenance

Objectives of preventive maintenance Elements of preventive maintenance

2. Preventive maintenance 3. Scheduled maintenance

• Advantages: Scheduled maintenance is a stitch-in-time procedure and

3. Scheduled maintenance 4. Break-down maintenance

Advantages of scheduled maintenance • Corrective or Breakdown maintenance implies that repairs

4. Break-down maintenance Predictive Maintenance

Disadvantages of corrective or break-down maintenance • In predictive maintenance, machinery conditions are

Maintenance costs • It is natural that when cost of preventive

Maintenance Jobs in Lathe Machine Maintenance Jobs in Lathe Machine

S.N. Parts Maintenance Jobs S.N. Parts Maintenance Jobs

5. Total Productive Maintenance (TPM) 5. Total Productive Maintenance (TPM)

5. Total Productive Maintenance (TPM) 6. Total Planned Quality Maintenance (TPQM)

6. Total Planned Quality Maintenance (TPQM)

TPQM addresses both programmatic and technical

Industrial Engineering and Management, BME III/I

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