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6ME6.3A: MAINTENANCE MANAGEMENT

Presentation · February 2016

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6ME6.3A: MAINTENANCE MANAGEMENT

UNIT - II Maintenance
 Maintenance is defined as:
Dr. Devendra Choudhary
“Combination of all technical, administrative
Department of Mechanical Engineering
and managerial actions during the life cycle
Govt. Engineering College Ajmer
of an item intended to retain it in, or restore it
to, a state in which it can perform a required
function.”

Maintenance Maintenance Management

 Maintenance includes actions such as
 cleaning, lubrication and topping up,
 adjustment and calibration,
 condition assessment,
 repairs and
 replacement.
 Maintenance enables to detect and prevent failures as
they would occur and hence increase system
reliability and availability.
 The effectiveness of maintenance is mainly assessed
by maintainability, availability and OEE measures.
 All activities of the management that determines
the maintenance objectives, strategies, and
responsibilities and implement them by means
such as maintenance planning, scheduling and
control of methods in the organization including
economic aspects.
 Maintenance management generally consists of the
following basic concepts:
 Setting aims and objectives
 Providing the means of attaining those aims and objectives
 Decision making

Maintenance Management Maintenance Management System

 Aims to retain the production means or
restoring them in the state that is considered
necessary for fulfillment of production function. Input Planning Organizing
Facilities
Maintenance
 It is a combination of art, science and Labour
Equipment process
Output

philosophy. Spare
Management

 It is a matter of having right resources at the

right place at the right time.
Feedback
 It ensures that all company assets meet and control

continue to meet the design function of the

Control of waste, material, cost and inventory
asset.

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Objectives of Maintenance Overall Equipment Effectiveness

 To enhance overall plant/equipment effectiveness  OEE = Availability x Performance x Quality
(OEE).  Availability = Run Time / Total Time
 OEE = Availability * Performance rate * Quality rate  Performance = Total Count / Target Counter
 To achieve acceptable safety of manpower and  Quality = Good Count / Total Count

nearby surrounding.  Availability takes into account any Down Time

 To ensure operational readiness of all equipment Losses.
at all the time and for emergency duty.  Performance takes into account any Speed
 To minimize cost. Losses.
 Quality takes into account any Quality Losses.

An Example of Calculating Simple OEE An Example of Calculating Simple OEE

Machine Data Values Machine Data Values Machine Data Values

Shift Length (8 hours) 480 minutes
Run Time 375 minutes Total Count 360
Run Time 375 minutes
Setup Time 15 minutes Good Count 355
Breaks 60 minutes
Down Time 30 minutes Target Count 400
Setup Time 15 minutes
Total Time 420 minutes Breaks 60 minutes
Down Time 30 minutes
Total Time 420 minutes OEE Variables Formula Result
Ideal Cycle Time 1 part every 63 secs Availability Run Time / Total Time (375/420) 89.29%
Total Count 360 Performance Total Count/Target Count (360/400) 90.00%
Good Count 355 Quality Good Count / Total Count (355/360) 98.61%
Target Counter 400 OEE Availability x Performance x Quality 79.24%

Maintenance Strategies Maintenance Strategies

Plant Asset Plant Asset
Maintenance Maintenance

Total Total
Productive Productive
Planned Maintenance Fixed time Planned Maintenance Fixed time
Maintenance Maintenance Maintenance Maintenance
Preventive Preventive
Maintenance Condition Maintenance Condition
Design-out based Design-out based
Maintenance Reliability Maintenance Maintenance Reliability Maintenance
Maintenance Centered
Maintenance Centered
strategies Maintenance strategies Maintenance
Opportunistic Opportunistic
Maintenance Maintenance

Unplanned Corrective/ Breakdown/ Unplanned Corrective/ Breakdown/

Maintenance Reactive Maintenance Maintenance Reactive Maintenance

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Corrective/Breakdown Maintenance
 Corrective or breakdown maintenance
implies that repairs are made after the
equipment fails to perform its normal
function.
 “fix it when it breaks”
 For example; an electric motor will not start,
a belt is broken etc.
 No actions is taken either to detect the onset
of failure or to prevent failures
Corrective Maintenance Procedure
Detection
Preparation for maintenance
Localization/ Isolation
Disassembly/ Access
Decide
Repair or Replacement of equipment
Reassembly
Alignment & Adjustment
Condition verification / check out
Disadvantage of Breakdown Maintenance
 Maintenance cost increases due to secondary
failures.
 Planning of tools, spares and manpower cannot be
done beforehand to perform maintenance actions.
 It is difficult to find the root cause of failures using
this strategy as it only attends the symptoms.
 Reactive maintenance comes with low cost
investment, but has a high production loss capability.
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Corrective/Breakdown Maintenance
Typical causes of equipment breakdown may
be as follows:
 Failure to replace worn out parts.
 Lack of lubrication.
 Neglected cooling system.
 Indifference towards minor faults.
 External factors such as too low or too high line
voltage, wrong fuel etc.
 Indifference towards equipment vibrations, unusual
sounds coming out of the rotating parts, equipment
getting too much heated up etc.
Disadvantage of Breakdown Maintenance
 Breakdown maintenance is most expensive one
due to:
 high machine downtime,
 low production availability,
 high overtime labour costs and
 high spare parts inventory cost
 Primary component failure causes secondary
damages (Connecting rod failure may cause failure of
valves, lining and shaft etc.)
Scheduled Preventive Maintenance
 PM carried out in accordance with
predetermined/established intervals of time or
number of units of use or other prescribed
criterion (Oil changing after 5000 KM).
 PM is time driven and periodicity of action is
decided based on MTTF statistic or the bathtub
curve.
 This means that the tasks are based on hours of
operation or elapsed time.
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Scheduled Preventive Maintenance Advantage of Preventive Maintenance

• Replacement of consumables and items that can
deplete.
 Allows planning of resources beforehand.
Servicing • Adjustment and Alignment
• Cleaning of permanent filters  Resource requirement and down time can be
• Replacement of expendable items (oil ring/ gas-kit) minimized.
On-condition • Evaluate physical condition of component/surfaces  No secondary damages.
that wear out or corrode
remedial • Condition assessment based on misalignment or  Number of unexpected breakdowns are reduced.
action excessive play
 Proactive comes with high investment cost, but
Verification of hidden function • Fuse lower frequency of production downtime.

Scheduled replacement • Oil changing after

5000 KM

How many times we do PM How many times we do PM

 The preventive maintenance cost increases when
the inspection and maintenance interval is Off line/ lost prod.
shortened by maintenance at the higher reliability Total cost of PM due to PM

level.
PM resource
 On the other hand, risk or loss caused by failure Cost
will increase when the inspection and
maintenance interval is lengthened.
Lost prod. due to
breakdown maint.
Breakdown maint.
resource
Production window (die changing or holiday)
Level of preventive maintenance

Assessment of maintenance need Assessment of maintenance need

 Items are classified with regard to six factors:
 Safety risk associated with breakdowns – S
High risk Low risk Insignificant risk
 Quality problems, customer complaints or scrap – Q S
 The extent of time during which the equipment are High risk Low risk Insignificant risk
used for production – T Q
 Obstacles that arise in the production process, which 24 hours/day 8-24 hours/day 8 hours/day
T
affect the lead time, due to the equipment
Cause a stop in the Don’t stop the process Don’t stop the
breakdown - O O whole process but cause losses process
 Failure frequency – F 1 failure/2 months 1 failure/2 -6 months 1 failure/6+
 Mean Time To Repair (MTTR) - M
F months
MTTR > 2 hrs 0.5 < MTTR < 2 hrs MTTR < 0.5 hrs
M

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ABC classification of equipments Selection of Maintenance Strategy

 Deterioration characteristic of the component,
MTTF
 Repair characteristic of the component, MTTR
 Economic factors such as material cost, repair
cost and cost of unexpected failure.
 Internal environment & statutory safety
regulations.
 Whether cause of failure is to be identified or not.
 Quality issues

Selection of Maintenance Strategy

Increasing risk of production losses due to stop

Fixed-time Condition-
Reactive Preventive based
C - category Preventive
B - category A - category

Increased investment in competence

Increased reward opportunities due to production possibilities

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