Maintenance Management

Outline
• Introduction
• Maintenance Objectives
• Costs / Impact of Poor Maintenance
• Functions of Maintenance
• Types of maintenance
• Planned maintenance
– Features of Planned Maintenance
– Basic Requirements of Planned Maintenance
• Breakdown maintenance
• Job Manuals
• Job scheduling
 Introduction
• Maintenance of facilities and equipment in good
working condition is essential to achieve specified
level of quality and reliability and efficient
working.
• Plant maintenance is an important service
function of an efficient production system.
• It helps in maintaining and increasing the
operational efficiency of plant facilities and,
• contributes to revenue by reducing the operating
costs and increasing the effectiveness of
production.
 Maintenance Objectives
Maintenance in any activity is designed to keep the
resources in good working condition or restore them to
operating status. The objectives of plant maintenance
are to :
• increase functional reliability of production facilities.
• enable product or service quality to be achieved
through correctly adjusted, serviced and operated
equipment.
• maximise the useful life of the equipment.
• minimise the total production or operating costs
directly attributed to equipment
service and repair.
• minimise the frequency of interruptions to production
by reducing breakdowns.
 Cost / Impact of Poor Maintenance
• Maintenance activities include all efforts to keep production
facilities and equipment in an good/ acceptable operating
condition.
• Failure or breakdown of machines and equipments in
manufacturing and service industries have a direct impact on
the following aspects:
• Production Capacity:
– The production capacity of the system is reduced by the machines idled
by failures/breakdowns.
• Production Costs:
– Poor maintenance leads to increase in production costs.
– Machine breakdowns increase the labour cost per unit due to idle
labour.
– Unit labour and material costs also increase when machine malfunctions
result in scrap/rejections.
– frequent breakdown of machines increases cost of maintenance, (costs
of providing repair facilities, maintenance crews, spare parts and
standby machines)
 Impact of Poor Maintenance
• Product and Service Quality:
– Poor maintenance of equipment leads to production of low quality products.
– cause frequent breakdowns and can not provide satisfactory service to
customers.
• Workers or consumer safety:
– Poorly maintained equipment or worn out equipment is likely to fail at any
moment and such failures can cause injuries to operators working on those
machines.
– Similarly products such as automobiles and two wheelers, if not properly and
periodically serviced may suddenly fail/breakdown and cause injuries to users.
• Consumer Satisfaction:
– when production equipments are on breakdown, work stoppages results in
delayed delivery of products to customer hence decreases consumer
satisfaction.
• Capital requirements required for replacement of machines.
 Functions of Maintenance
• The important functions of maintenance can be summarized as
follows:
• To develop maintenance policies, procedures and standards for the
plant maintenance system.
• To schedule the maintenance work after due consultation with the
concerned production departments.
• To carry out repairs and rectify or overhaul planned equipment /
facilities for achieving the required level of availability and optimum
operational efficiency.
• To ensure scheduled inspection, lubrication oil checking, and
adjustment of plant machinery and equipment.
• To document and maintain record of each maintenance activity (i.e.
repairs, replacement, overhauls, modifications and lubrication etc)
• To develop management information systems, to provide information
to top management regarding the maintenance activities.
 Functions of Maintenance
• To maintain and carry out repairs of buildings, utilities, material handling
equipments and other service facilities such as electrical installations,
central stores and roadways etc.
• To carry out and facilitate periodic inspections of equipment and facilities
to know their conditions related to their failure and stoppage of
production.
• to prepare inventory list of spare parts and materials required for
maintenance.
• to ensure cost effective maintenance.
• To forecast the maintenance expenditure and prepare a budget and to
ensure that maintenance expenditure is as per planned budget.
• To recruit and train personnel to prepare the maintenance work force for
effective and efficient plant maintenance.
• To implement safety standards as required for the use of specific
equipment or certain categories of equipment such as boilers, overhead
cranes and chemical plants etc.
 Functions of Maintenance
In terms of plants operations the functions of maintenance are:
• The plant must be available as and when required.
• The plant must not breakdown during actual operation state.
• The plant must operate in an efficient manner at required level of plant
operation.
• The down time must not interfere with production runs & it should be a
minimum
• To accomplish these conditions there must be complete cooperation and
mutual understanding between maintenance and production
departments.
• There must be an effective maintenance policy for planning, controlling
and directing all maintenance activities.
• The plant maintenance department must be well organized, adequately
staffed sufficiently experienced and adequate in number to carry out
corrective and timely maintenance with the efforts in minimizing
breakdowns.
Types of maintenance
• Planned maintenance
• Breakdown maintenance
• Corrective maintenance

• Routine maintenance
• Preventive maintenance
• Predictive maintenance
• Condition based maintenance
• Design-out maintenance
 Planned Maintenance
• Planned maintenance is also known as scheduled
maintenance or productive maintenance.
• Breakdown does not occur in a planned manner but
maintenance work can be planned well in advance.
• It is an organized maintenance work carried out as per
recorded procedures having control.
• Planned maintenance involves the inspection of all plants and
equipments, machinery, according to a pre-determined
schedule in order to overhaul, service, lubricate or repair
before actual breakdown in service occurs.
• The purpose is to reduce the machine stoppage due to
sudden breakdown requiring emergency maintenance.
 Features of Planned Maintenance
• A maintenance work which is well organized and preplanned.
• It is carried out with prior planning, foresightedness controls
and records.
• It is carried out in a scientific way.
• It covers comprehensive planning as well as the execution
part for any job concerning maintenance.
• It is generally carried out according to some pre-defined
maintenance programme,
• It is applicable to any type of maintenance work such as
corrective, preventive as well as replacement work.
 Basic Requirements of Planned
Maintenance
• A well defined maintenance policy is to be
followed.
• Maintenance policy planned in advance is
applicable.
• The maintenance work is to conform to the
pre-decided maintenance plan.
• Historical and statistical records which are
compiled and maintained provide guidelines
for future maintenance policy.
 Basic Requirements of Planned
Maintenance
• Whenever a policy of planned maintenance is practiced the planning is
mainly of financial nature.
• It has to be ensured that sufficient funds are available for providing man-
power, machines and other inputs required for planned maintenance.
• The following factors would help in deciding the planned maintenance:
– What is to be maintained i.e. the individual item of the plant and equipment
to be maintained.
– The details of how each item is to be maintained i.e. method to be adopted.
– What maintenance resources would be needed i.e. man-power, tools, spares
and test equipment etc to carry out the maintenance work.
– The frequency of carrying out maintenance inspection,
– The method of analysis, rectification and control must be pre-decided in order
to evaluate the performance of maintenance system and improvements if
possible.
 Breakdown maintenance
• Breakdown maintenance.
– It is an emergency based policy in which the plant or
equipment is operated until it fails and then it is brought
back into running condition by repair.
– The maintenance staff locate any mechanical, electrical or
any other fault to correct it immediately.
– The break down maintenance policy may work good and
feasible for small factories where,
• There are few types of equipment.
• Machines/equipments are simple and does not require any
specialist.
• Where sudden failure does not cause any serious financial loss.
 Difference Between Breakdown and
Emergency Maintenance
Emergency maintenance
• It is always unplanned.
• The nature of failure is very serious.
• No time lag is allowable.
• Recovery time is given top priority.
• Generally occurs in pressure vessels
such as boilers or turbines where
the risk involved is very high.
• Implementation is very urgent and
corrective in nature with available
resources.
• The delay in implementation may
be serious.
Breakdown Maintenance
• It may be planned or unplanned.
• The nature of failure is normal or not
very serious.
• Permissible time lag may be allowed.
• Maintenance cost is the first priority.
• Generally occurs in general
engineering work, where the delay in
timely repair is not very risky.
• Implementation is not very urgent but
corrective in nature.
• The effect of delay in implementation
is not very serious.
 Job Manuals
The following steps are generally involved in preparing the job manuals :
• List of all major and medium maintenance jobs of the plant are prepared
and they are properly coded for identification.
• For each coded job, a separate job manual is to be prepared which
includes the
following :
– Sequence-wise break of the job in to activities with instructions to carry out those
jobs
– List of tools, tackles, spares and consumables needed to perform the activity
– List of jigs and fixtures and handling facilities for each activity
– Safety instructions
– Time estimate for the job or job activities
– Make available the manuals to all the users and update the manuals as and when
needed.
 Job scheduling
• Scheduling deals with "who" and "when
– i.e., who is to do the job and when the job is to be started.
• Realistic schedules are the functions of realistic thinking,
availability of the data and records.
• The scheduler should obtain knowledge about the following facts
before starting his job:
– Availability of competent manpower- by trade, location, shifts etc.
– Availability of equipments, spares and proper tools where the work is to be
carried out.
– Starting data for the job and past schedules and charts.
– Scheduling techniques like bar charts and network techniques are used.
 Systematic maintenance
The various elements of systematic maintenance are :
• Codification and Cataloguing
• Equipment/machine history cards and sheets
• Instructions manuals and operating manuals.
• Standard operating practices and work instructions.
• Maintenance time standards (MTS)
• Maintenance —Operation liaison
• Maintenance work order and work permit
• Job cards and job cards procedures
• Job execution, monitoring, feed back and control
• Maintenance records and documentation
 Tradeoff Between Repairs and PM
• At minimum level of PM, it is a remedial policy
– fix machines only when they break
– the cost of breakdowns, interruptions to
production, and repairs is high
• As the PM effort is increased, breakdown and
repair cost is reduced
• At some point, the total maintenance cost
(PM, breakdown, and repair) reach a
minimum
 Trade off Between Repairs and PM
Annual Cost ($)

Minimum Total
Maintenance Cost
Total
Maintenance
Costs
Minimum
Level of Preventive
Preventive Maintenance
Maintenance Cost
Breakdown
and Repair
Cost
Maintenance Activity
Cost ($)

Minimum
Total Cost
of Repairs Total Costs
of Repairs
Cost of Repair
Crews & Shops,
Spare Parts, and
Standby Machines
Cost of
Interruptions to
Production
0
Making Repairs
 Corrective maintenance
• Corrective maintenance.
– This is an organized maintenance work intended to restore a
failed unit.
– It includes different types of actions like typical adjustments to
redesign of equipments.
– It is a one-time job and each corrective maintenance activity
undertaken should be completed fully.
– Each corrective maintenance job may differ from the other.
– The emphasis in corrective maintenance is on obtaining full
information of all breakdowns and their causes.
– Efforts are made to identify and eliminate the cause by activities
such as improving maintenance practices, changing frequency of
maintenance services and improving process control procedures.
 Routine maintenance
• Routine maintenance.
– It is the simplest form of planned maintenance,
which is very essential.
– Routine maintenance means carrying out minor
maintenance jobs at regular intervals.
– It involves minor jobs such as cleaning, lubrication,
inspection and minor adjustments.
– Routine maintenance needs very little investment in
time and money.
 Preventive maintenance
• Preventive maintenance.
– Preventive maintenance is a planned
maintenance of plants and equipments in order to
prevent or minimize the breakdown.
• Predictive maintenance.
– Predictive maintenance as the name implies
simply means predicting the failure before it
occurs, identifying the root causes for those
failures symptoms and eliminating those causes
before they result in extensive damage of the
equipment.
• Condition based maintenance. In this method, the condition of
the equipment or some critical parts of the equipment are
continuously monitored using sophisticated monitoring
instruments so that the failure may be predicted well before it
occurs and corrective steps are taken to prevent failure.
• Design-out maintenance. It is a design oriented curative means
aimed at rectifying a design defect originated from improper
method of installation or poor choice of materials etc. It calls for
the strong design and maintenance interface. Design out
maintenance aims to eliminate the cause of maintenance. It is
suitable for tems/Equipment of high maintenance cost.
 Preventive Maintenance System
• The preventive maintenance policy is a system of planned and
scheduled maintenance.
• The basic principal involved in this system is “prevention is
batter than cure". Preventive maintenance includes :
– Proper identification of all items, their documentation and
coding
– Inspection of plant and equipments at regular interval
(Periodic inspection)
– Proper cleaning, lubrication of equipments.
– To upkeep the machine through minor repairs, major
overhauls etc.
– Failure analysis and planning for their elimination.
 Preventive maintenance

• Preventive maintenance schedules are

normally of two categories:
• Fixed time maintenance (firm) schedule.
• Condition based maintenance.
 Preventive Versus Breakdown
Maintenance
• Preventive maintenance is the routine inspection and service activities
designed to detect potential failure conditions and
• make major adjustments or repairs that will be help prevent major operating
problems where as, breakdown maintenance is the emergency repair and it
involves higher cost of facilities and equipments that have been used until they
fail to operate
• An effective preventive maintenance programme for equipments requires
– properly trained personnel,
– regular inspection and service and
– should maintain regular records.
• It is planned in such a way that it will not disturb the normal operations, hence
no down time cost of equipment.
• Breakdown maintenance stops the normal activities and the machine as well
as the operators is rendered ideal till the equipment is brought back to normal
condition of working
 Condition Based Maintenance (CBM)
System
• Predictive maintenance is more feasible today because of
technology that available for equipment surveillance and diagnosis
of problems while the machines are still operating.
• The condition of a machine can be monitored by several means.
• Sensors may be installed, or periodic readings may be taken with
portable units to measure vibration or temperature.
• Vibration sensors and ultrasonic sensors are used to feed data in to
a computer for analysis.
• The deviation from the normal vibration pattern are recorded when
the machine is running properly are analyzed to determine where
the problem is developing and when it will become serious.
• A problem of this type prevents unplanned downtime that disrupts
production schedules.
 condition-based maintenance
• The objectives of condition-based maintenance
are :
– To detect the failures before they occurs.
– To carry out maintenance only when required.
– To reduce the maintenance costs and downtime
costs.
 The methodology of C.B.M. consists
of following steps :
• Proper identification and location of machines/equipments by codification.
• Selection of critical machines and systems.
• Identifying components/elements.
• Fixing condition parameters.
• Monitoring techniques.
• Monitoring schedule and frequency.
• Trend monitoring.
• Repair schedule and execution.
• Follow up.
• The conditioning monitoring techniques are broadly classified as
• Visual
• Temperature
• Vibration
• Lubricant monitoring
• Leakage monitoring
 Basic Maintenance Decisions
• Centralized versus decentralized maintenance
• Contract versus in-house maintenance.
• Repair verses replacement
• Individuals versus group replacement
• Standby equipments
• Amount of maintenance capacity
• Preventive versus predictive maintenance.
Industrial Engg & Operations Management by
Sharma
Industrial Engg & Production Management by
Martand Telsang