MM ZG513 Maintenance Engineering

BITS Pilani
Pilani Campus

Girish Kant Department of Mechanical Engineering

MM ZG513, Maintenance Engineering, Lecture-1, 24/07/2013

BITS Pilani
Pilani Campus

Introduction and Objectives

Chapter - 1

What is Maintenance?
Maintenance is an age old function which developed &

progressed, knowingly or unknowingly, along with the

operation of equipments. Maintenance refers to all the activities which assist in keeping plant & equipment in good condition. Any activity such as tests, measurements, replacements,

adjustments and repair, intended to restore or retain a

functional unit in a specified state in which the unit can perform its required functions.
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Maintenance Definitions
Maintenance is not merely preventive maintenance, although this aspect is an important ingredient. Maintenance is not lubrication, although lubrication is one of its primary functions. Maintenance simply a frenetic rush to repair a broken machine part or building segment, although this is more often than not the dominant maintenance activity.

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Maintenance Definitions
Maintenance is a science since its execution relies, sooner or later, on most or all of the sciences. It is an art because seemingly identical problems regularly demand and receive varying approaches and actions and because some managers, foremen, and mechanics display greater aptitude for it than others show or even attain.

It is above all a philosophy because it is a discipline that can be applied depending upon a wide range of variables that frequently transcend more immediate and obvious solutions. MM ZG513, Maintenance Engineering,
Lecture-1, 24/07/2013

BITS Pilani, Pilani Campus

Maintenance Definitions
Maintenance is a philosophy because it must be carefully fitted to the operation or organization. it serves as a fine suit of clothes is fitted to its wearer because the way it is viewed by its executors will shape its effectiveness. A set of activities that ensure any physical asset to continue its intended functions to the standard of performance desired by the user.

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History of Maintenance
Pre world war II (pre 1945) 1945-1970 1970 onwards

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Maintenance Objectives
Operational
Maximum operating efficiency of plant Maximum availability of plant High Quality performance Safety To maintain a plant clean & good appearance To extend Plant life to the last limit To reduce environmental impact due to machinery etc To provide service that will avert all breakdowns at all times at any cost.

Cost
Minimize maintenance expenditure and maximize profits To provide activities with in the limits of budgetary control

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Maintenance Benefits
Financial Organizational Technical

Human
Customer relations

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BITS Pilani, Pilani Campus

Financial Benefits
Extended Plant Life Uninterrupted production Improved quality of production

Reduced production delays

Reduced cost of repairs

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BITS Pilani, Pilani Campus

Organizational Benefits
Co-ordination between production and maintenance Man power planning Planning of deliveries

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BITS Pilani, Pilani Campus

Technical Benefits
Improved equipment suitability Build up of technical data Improved maintenance schedules

Improved plant condition

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BITS Pilani, Pilani Campus

Human considerations Benefits

Increased Safety Improved House keeping Less friction between relationships

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Customer relationship Benefits

Reliable delivery calls Show case house keeping

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Maintenance Policy
Scope and limits of maintenance Type and level of service expected Responsibilities to management

Personal Practices
Trade union contracts Budget and financial controls

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BITS Pilani, Pilani Campus

Maintenance Functions
Primary Functions Maintenance of existing plant equipment Maintenance of existing plant buildings and grounds Equipment inspection and lubrication Utilities generation and distribution Alterations and new installations Secondary Functions Storekeeping Plant protection Waste disposal Salvage Insurance Other services
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BITS Pilani, Pilani Campus

What does maintenance really do?

Repair, lubrication, overhaul, inspection, replacement of parts Training of the maintenance staff Training of the production staff Testing parts for suitability Planning of servicing schedules Improvement and modifications of plant Production of spare parts

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BITS Pilani, Pilani Campus

Maintenance System of Today

Protecting the buildings, structures and plants. Increase equipment availability & reducing downtime. Controlling & directing labour forces. Economy in maintenance department. Maximum utilization of available resources. Preparing maintenance budgets. Emphasis on waste recovery. Improving technical communication. Preventing waste of tools, spare and other materials.
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For achieving these objectives various control functions & actions are to be taken which would be discussed in subsequent chapters.

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Thanks

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BITS Pilani, Pilani Campus