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Maintenance UNIT - 1
Maintenance UNIT - 1
Maintenance UNIT - 1
PLANNING:
It is the process of determine how the organization can get where it wants to go.
The basic purpose of planning is to reduce the risk of uncertainties and to initiate a
coordinated effort with in the organization for the purpose of organizational
success.
Planning ensures the smooth operation of the system.
Three types of planning in Engineering system
1.Long Range Plan (span of 5 to 10 Years)
2.Short Range Plan (shorter period of time say 1 or 2 years)
3.Planning for Immediate Activity (It is a routine activity and it is done at the
working level when required )
Maintenance Planning :
Maintenance planning is the task of organizing resources to carry out a job
satisfactorily at reasonable cost within a specified period of time.
Maintenance planning should be carefully designed in such a manner it is able to
tackle the emergency maintenance as well as to ensure that maintenance workforce
is fully utilized.
PRINCIPLES OF MAINTENANCE:
Maintenance principles are followed in a system to guide the staff to work efficiently
and effectively to achieve the overall objectives .
The main areas of work governed by these principles are:
1.Plant management in maintenance work : Main role of the maintenance function is
to provide safe and effective operation of the equipment to achieve the desired targets
on time with economic usage of resources.
2.Production and maintenance objectives: The achievement of desired goals of the
production system is to be supported by both the production and maintenance
department to ensure smooth and successful operation of the industry.
3.Establishment of work order and Recording system: Work order for the maintenance
function indicates the nature of work to be performance and the series of operations to
be followed to execute a particular job. It is necessary to maintain proper records and
entries to monitor the maintenance function. This record is useful in formulating the
future maintenance plans and to meet the desired objectives of the organization.
4. Information Based Decision Making: The information is used to meet the man power
and spare parts requirements of the industry.
5.Adherence to planned maintenance strategy: It includes the use of manufacturers
information on the life and maintenance schedules of the equipment and other
materials resources available.
6.Planning of maintenance functions: All the maintenances functions are to be carefully
executed by way of proper planning to ensure the effective utilization of manpower
and materials.
7.Manpower for maintenance: The manpower requirements should also satisfies the need
arising in cases of overhauls, component replacement, emergency and unscheduled
repairs.
8.Workforce control: Determination
of exact workforce required to meet the
maintenances objectives of the system is difficult task due to the element of
uncertainty
9.Role of spare parts: The system should have good quality tools and that tools available in
required quantities to ensure the proper function of the maintenance works.
10.Training of the maintenance work force; Training helps the workforce to learn about the
modern techniques, recent trends in maintenances, Knowledge of sophisticated
instruments and to chalk out a strategy to meet the growing demands of the industry.
VARIOUS FACTOR TO BE CONSIDERED IN MAINTENANCE PLANNING:
1.Job Distribution: The first and foremost task in maintenance planning is the distribution
of the jobs to the personnel for preventive and emergency maintenance works. The
distribution is also to ensure that neither underutilization nor over utilization of
resources is done.
2.Programme: It is a well formulated combination of the available skills and resources that
ensures optimum and appropriate utilization to meet the objectives of the organization.
Maintenance programme involves
a. Selection of activities for maintenance
b. Determination of the frequency of preventive maintenance
c. Decision on the cost effective methodology
3. Manpower Allocation: The central idea of manpower allocation can be drafted using
the information available about the skill level of personal deputed for the
maintenance and planning the task to meet the objectives and to keep reliable
records for analysis of results of maintenance.
4.Staffing: Staffing is dependent upon the ability of the organization to tackle the regular
as well as attending the unforeseen situation. Staffing should be sufficient to handle
preventive and emergency maintenance task
5.Planning Techniques; Planning techniques are required to develop the overall master
plan, for scheduling and execution. Planning methods are Gantt charts, milestone
method, critical path method9CPM0, Programme Evaluation Review
Techniques(PERT).
6.Planning Procedures Four steps in planning procedures
a. Organizing maintenance resources to ensure their effective use in future
b. Scheduling the resources for the planned period
c. Execution of plans according to the schedules
d. Establishing a feedback system for all the above processes to identify the
deficiences of each process
7.Estimation of maintenance works: It is used to find out the quantity and quality of the
maintenance work. This will help in allocation of the required manpower.
8.Maintenance Control; Maintenance control is the auditing technique to ensure the
effective utilization of maintenance budget. This accountability controls and
improves the quality of manpower and material utilization in an organization.
Combined preventive maintenance and emergency maintenance planning:
If the maintenance planning need both the preventive and emergency demands then it
should follow the three factors
(a) Organizational Goals: Maintenance planning must be in accordance with that of
the organization goals. Maintenance Needs Analysis(MNA)should be carried out to
identify the role of piece of equipment or asset in achieving the desired objectives of
the organization. The planned work should be executed out to improve the
performance of the production system.
(b)Policies: Fault oriented maintenances policies are evolved by the maintenances
department. The policies must be well defined so that timely implementations of
maintenance functions are ensured.
( c) Procedures: The procedures of the work must be well defined and standardized
without any confusion to the workforce. The development of procedures includes
the design of the inspection form, interval of reporting, issues of maintenance tools
etc.
Importance and Benefits of sound maintenances Management systems:
The profit of any industry depends solely on the return on the investment. The capital
cost and operating costs are the major factors in any industrial investment. The
higher return on investment is possible to achieve only if the equipment and other
machineries are in proper working condition to meet the designed as well as desired
levels of performance.
Various Benefits of sound maintenances Management systems are
1.Minimization of downtime
2.Improvement in availability of system
3.Extended life of equipment
4.Safety and smooth operation of the process
5.Provide adequate back up supply
6.Minimization
3.Duration of adequate performance: It is used to state the time up to which the desired
performance of the system is achieved under the given operating conditions.
4.Environmental or Operating conditions: It indicates the prevailing conditions at which
the system is under operation.
Reliability is the probability of a device performing its purpose adequately for the period
intended under the given operating condition
Two types of reliability
1. Inherent reliability ; It is associated with the quality of the material and design of
machine parts
2.Achievable Reliability : It depends upon other factors such as maintenances and
operation of the equipment.
The total reliability of any equipment is a function of design , maintenance and field
operational reliability.
Machine Availability: The availability of a machine or service over a specified time can be
represented as
UT
A
UT DT
Where
A is the availability of the machine over a specified time
UT is the machines uptime during the specified time
DT is the machines downtime during the specified time
UPTIME : Up time of a machine / service is thus the time for which it is actually
available to complete the desired function.
DOWNTIME; Downtime or outage of a machine is the period of time during which it is
not in an acceptable working condition.
The availability of equipment in terms of its working effectiveness called as operational
availability(OA)
Availability is the ratio of the time at which equipment is available for the designated
operation/service to the total time of operation and maintenance of the equipment
Three types of availability based on the time element:
1.Inherent Availability: It is the probability that a system or equipment shall operate
satisfactorily when used under prescribed conditions in an ideal support
environment without any scheduled or preventive maintenance at any given time
Inherent availability = MTBF / (MTBF+MTTR)
ideal support environment means the ready availability of tools, spare parts ,
manpower, manual etc.
2.Achieved Availability: It is the probability that a system or equipment shall
operate satisfactorily when used under prescribed conditions in an ideal support
environment without any scheduled or preventive maintenance at any given time
OT IT
OA
OT IT AD RT
Where
OT is the operating time
IT is the idle time
AD is the administrative delay or operational delays
RT is the repair time
= 1/ MTTR
MTTR
Mean Waiting Time(MWT): Mean waiting time is the ratio of Total machine hours lost
due to waiting for materials or labour to the total number of breakdowns.
Mean waiting time is part of the down time indicating the mean down-time lost in waiting
for materials or labour for attending to a break down
Increased mean waiting time will help the management in identifying the areas for
improvement such as organizing of trade force or improving the stores systems &
procedures or improving the spares parts control systems.
MAINTENANCE ORGANIZATION: The word organization is derived from the
organism which means an organized body with connected interdependent parts
sharing common life. Organization is a mechanism or structure which helps the
activities to be performed effectively.
Organization is the detailed arrangement of work and working condition in order to
perform the assigned activities in an effective manner.
Organization is the form of every human association for the attainment of a common
purpose.
2.
3.
Uniform distribution of
department
4.
5.
Proper knowledge about the technical expertise/ experience of the workers deputed
for the particular job
6.
Proper training of the staff of maintenance to meet the growing demands of the
industry and to catch up with the modern trends in maintenance
7. Designing the policies and procedures at an early stage to help the maintenance
department to achieve the goals of the industry.
MAINTENANCE ENGINEERING
Fixed cost: This includes the cost of support facilities including the maintenance staff
Variable cost: This includes the consumption of spare parts, replacement of components
cost of other facilities required to meet the requirement of maintenance.
MAINTENANCE BUDGET: The maintenance budget is used to set certain amount of
money to meet the expenditure incurred in achieving the objectives of maintenance.
1.Appropropriation Budget: Budget used to allocate money for each activity
independently
2.Fixed Budget: Fixed used to allocate money for a specified period of time
3. Variable Budget: Dynamic allocation of expenditure based on maintenance
requirement and activities.
MAINTENANCE ENGINEERING
FACTORS INVOLVED IN MAINTENANCE BUDGET:
1.
Data on failure, downtime cost due to equipment breakdown, cost of damage, loss of
production, penalty cost due to delay delivery, replacement cost spare parts and
material cost, wear and tear
2.
3.
The cost involved in hiring the maintenance personal outside the organization to
carry out the specific tasks of maintenance needs
4.
Equipment overhaul schedule is to be carried out in time that will improve the
performance of equipment and many enhance its service life
5.
Expenses associated with fuel, oil, wages and maintenance of older machine
6.
7.
Operating hours
END OF THE FIRST UNIT
Dr.T.Rajesh Kannah, Department of Mechanical Engineering
ANJALAI AMMAL-MAHALINGAM ENGINEERING COLLEGE,
KOVILVENNI-614 403.