Maintenance Genesis

Presented by :
Group 2 (Batch 18B)
Group 2- Members

1. Richa KH2009SMBA18P038
2. Venkatesh KH2009SMBA18P054
3. Diptesh KH2009SMBA18P066
4. Jasmeet KH2009SMBA18P070
5. Ramya KH2009SMBA18P101
6. Ankur KH2009SMBA18P104
Maintenance Genesis
Genesis
• A beginning or origin of anything

Maintenance
• It is the work of keeping something in proper
condition
Breakdown Consequences
•Production capacity is reduced
•Orders are delayed
•No production
•Overhead continues
•Cost per unit increases
•Quality issues
•Product may be damaged
•Safety issues
•Injury to employees
•Injury to customers
Goal of Maintenance

•To keep production systems in good working

condition at minimal cost
•To ensure maximum ‘availability’ of the operation

•Reasons for maintenance

•To avoid production or service disruptions
•To not add production or service costs
•To maintain high quality
•To avoid missed delivery dates
Availability

Reliability 
•Probability that the item will not fail

Maintainability
•The probability that the item is successfully restored
after failure

Availability
•Probability that a system is not failed or undergoing a
repair action when it needs to be used
Maintenance Management Prior to World War II

•Reactive Maintenance
•Breakdown maintenance
•Reactive approach
•Dealing with breakdowns or problems when
they occur

Challenges :
• Poor planning
• Incomplete repair
Maintenance Management Post World War II
Year - 1950

Preventive Maintenance
•To prevent the failure of equipment before it actually
occurs through:

Periodic maintenance ( Time based maintenance -

TBM)

Predictive maintenance
Periodic maintenance
 Time based maintenance (TBM)

•Servicing and cleaning equipment

•Inspection
•Oiling
•Replacing parts
Predictive maintenance
Service life of important part is predicted based on :
Inspection
Diagnosis

Parts are used to the limit of

their service life.

It involves condition based maintenance.

Measures and analyze data about deterioration.
Monitor conditions through on-line system.
Condition Based Maintenance (CBM)
To assess machinery condition it uses:
•Non destructive testing techniques
•Visual inspection
•Performance data
Ultimate Goal of CBM:
Eliminate routine maintenance
Service equipment only when monitoring system
indicates
Key components of CBM:
•Vibration monitoring
•Thermography
•Oil analysis
Vibration monitoring
Monitors frequencies to predict impending defect

Compares the vibration spectra of new equipment vs.

subject equipment
Thermography
Analysis of thermal information by using non contact
thermal imaging devices.

Worn refractory insulation causing hotspot

Oil Analysis

Detecting the presence of contamination in oil.

Example:
• Electrical transformer’s oil analyzed for the presence of
carbon deposits
• Analyzing High Engine Oil consumption
Benefits of preventive maintenance
Improved system reliability.
Decreased cost of replacement.
Decreased system downtime.
Better spares inventory management.
When Does Preventive Maintenance Make Sense

Condition 1:
The component in question has an increasing failure rate.

Condition 2:
The overall cost of the preventive maintenance action
must be less than the overall cost of a corrective action
Quick Recap
1957 - Corrective Maintenance
Equipment with design weakness must be redesigned to
improve:
Reliability
Maintainability
Preventive Maintenance

Analyzing techniques:
FMEA
Root cause analysis
Failure Mode and Effects Analysis

A methodology to analyze and discover:

All potential failure modes of a system

The effects these failures have on the system

How to correct and or mitigate the failures or effects
on the system.
Root Cause Analysis
Root Cause
Fundamental breakdown or failure
When resolved, prevents recurrence of the problem.
Techniques:
•“Why-Why” Analysis
•Causal Tree
•Fish Bone Diagram
Year - 1960
Poka-yoke - Eliminates defects

By preventing or correcting mistakes as early as possible.

Applied in processes potential of inducing catastrophic in-

service failures.

“I have an extra
part. I must
have omitted a
step!”
 
1960 - Maintenance prevention
It indicates the design of a new equipment.
Weakness of current machines are sufficiently studied and
incorporated before commissioning a new equipment.
Prevents Maintenance
Improves “Availability”

Example:
-Using powder metallurgy built porous bronze bearing for
ceiling fans

- Improved automobile batteries

1963 - Productive Maintenance

Preventive maintenance
+
Maintenance prevention = Productive maintenance
+
Maintainability Improvement

Maximize plant and equipment effectiveness

Achieve optimum life cycle cost of

production equipment.
1971 - Total Productive Maintenance
Motives of TPM
•Adoption of life cycle approach ,improving the overall performance
of production equipment.

•Improving productivity by highly motivated workers ,achieved by

job enlargement.

•The use of voluntary small group activities for identifying the cause
of failure, possible plant and equipment modifications.
Uniqueness of TPM

The concept of "I (Production operators) Operate, You (

Maintenance department ) fix" is not followed.
TPM Objectives

Zero Defects
 Zero Breakdown
Zero accidents
Involve people in all levels of organization.
Direct benefits of TPM

Obtain Minimum 80% OPE

Obtain Minimum 90% OEE

Rectify customer complaints.

Reduce the manufacturing cost by 30%.
Satisfy the customer’s needs by 100 %
Reduce accidents.

Follow pollution control measures.

Indirect benefits of TPM

•Higher confidence level among the employees.

•Keep the work place clean, neat and attractive.
•Favorable change in the attitude of the operators.

•Achieve goals by working as team.

•Horizontal deployment of a new concept in all areas of the
organization.
•Share knowledge and experience.

•The workers get a feeling of owning the

machine.
Bath Tub Curve
1975 - Life Data Analysis (Weibull Analysis)

Leading method in the world for fitting life data.

The three-parameter Weibull’s expression is given by:

Where,
η = scale parameter,
β = shape parameter (or slope),
γ = location parameter.
Weibull Analysis Advantages

Provides reasonably accurate failure analysis and

failure forecasts with extremely small samples.

Provides a simple and useful graphical plot of the

failure data.
Weibull Interpretation
β<1 β=1
• Implies failures are
• Implies infant mortality random
An old part is as good as
a new part
1<β<3 β>3
• Occurs for:
­Low cycle fatigue • Implies rapid wear out in
­Most bearing and gear old age
failures
­Corrosion or Erosion • Occurs for:
• Wear-through
1986 – Six Sigma
Integrated TPM model and Six Sigma concept
leads to an improved model of the maintenance process.
It uses all advantages of the TPM approach
Enables reduction of variations in the process
Eliminates the occurrence of errors
Reduces the time cycle of the
maintenance process
Maintenance in IT Environment
IT System Maintenance shall be performed for the
following reasons:
To correct errors
To keep system current
To improve the system
Why Software/Hardware Maintenance ?
To provide continuity of service
To support mandatory upgrades
To support user requests for improvements
To facilitate future maintenance works
Data Backup
Maintenance Decision Diagram
Maintenance Strategy Model
Challenges facing Modern Maintenance

Selection of most appropriate techniques

Dealing with each type of failure process

Fulfilling the expectations of the owners and users

Cost-effective & enduring maintenance
Involvement & active participation of

all persons concerned and connected

Changing maintenance techniques at present

• Condition monitoring of equipment developed

• Machines design based on reliability and maintainability

• Hazard studies carried out

• Small fast computers & systems came into existence

• Failure mode and effects analysis (FMEA) developed

• Multi-skilling & team work became the goal and practice
• Need based training program e.g. Industrial basic
training, TPM, TQM, Quality circle, 5-S became popular
Management of Maintenance
Monitor the work progress daily, weekly or monthly
Identify any significant variance in following through
exception reporting.
•Labor hours
•Work order costs
•Total maintenance cost asset

Develop alternative solutions or actions to reduce

time and costs.
THANK YOU !