MAINTENANCE

MANAGEMENT
BY
Md. Nahid Parvez
WHAT IS MAINTENANCE?
 MAINTENANCE IS THE PROCESS OF KEEPING
MACHINE AND EQUIPMENT IN GOOD WORKING
CONDITION SO THAT THE EFFICIENCY IS
RETAINED AND ITS LIFE IS INCREASED.
 IT’S A COMBINATION OF ACTIONS CARRIED
OUT BY AN ORGANIZATION TO
REPLACE,REPAIR,SERVICE THE
MACHINES,COMPONENTS OR THEIR GROUPS
IN A MANUFACTURING PLANT,SO THAT IT
WILL CONTINUE TO OPERATE
SATISFACTORILY.
FUNCTIONS OF
MAINTENANCE
a) INSPECTION
b) REPAIR
c) OVERHAUL
d) LUBRICATION
e) SALVAGE
ফাংশন অফ মেইন্টেন্যন্স:

১। পরিদর্শন
২। মেরামত করা
৩। নতু ন করে সাজান(OVERHAUL)
৪। তৈলাক্তকরন
INSPECTION
 PERIODIC CHECKING OF MACHINES
 GIVING PROPER ATTENTION TO THOSE
EQUIPMENTS REQUIRED WORK IN INTERVALS
 DETERMINATION OF REPAIR FEASIBILITY
 CONTROL OF QUALITY WORK
 DETECTION OF FAULTS BEFORE BREAKDOWN
OF EQUIPMENT
REPAIR
 PROCESS OF REPARING THE COMPONENT OR
REPLACING THE ITEM OR PART BY ANOTHER
ITEM TO RESTORE FAILED OR BROKEN DOWN
ITEM IN WORKING ORDER.
OVERHAUL
 FALLS UNDER PREVENTVE MAINTENANCE .
 FREQUENCY OF OVERHAULING IS LESS THAN
LUBRICATION AND INSPECTION.
 HERE THE MACHINE IS STRIPPEDAND THE VARIOUS PARTS
ARE CLEANED AND OILED AND COMPONENTS ARE
REPLACED.
LUBRICATION
 HELPS IN MAINTAINING THE MACHINE
ACCURACY AND INCREASE LIFE OF MACHINE.
 IT IS DONE BY THE OPERATOR ITSELF.
 LUBRICATION CAN BE
DAILY,WEEKLY,FORTNIGHTLY,MONTHLY.
MAINTENANCE PRACTICES
 DIFFERENT MAINTENANCE PRATICES ARE
ADOPTED TO SUIT THE VARIOUS TYPES OF
PRODUCTION MACHINERIES AND OTHER
DEVICES.THEY ARE:-
I. BREAKDOWN MAINTENANCE
II. PREVENTIVE MAINTENANCE
III. CORRECTIVE MAINTENANCE
IV. PRODUCTIVE MAINTENANCE
মেইন্টেন্যন্স প্রকারভেদ:

 সাধারণত চার প্রকার:-

১। ব্রেকডাউন মেইন্টেন্যন্স
২। প্রিভেন্টিভ মেইন্টেন্যন্স
৩। কারেক্টিভ মেইন্টেন্যন্স
৪। প্রডাক্টিভ মেইন্টেন্যন্স
1.BREAK DOWN MAINTENANCE
 MACHINES ARE ALLOWED TO RUN WITHOUT
CARRYING OUT ANY MAINTENANCE.
 ONLY WHEN IT BECOMES OUT OF
ORDER(STOP WORKING) IT IS REPAIRED
 NEXT MAINTENANCE IS DONE ONLY WHEN IT
BREAKS DOWN.
 APPLICABLE TO MACHINES WHICH ARE NOT
IMPORTANT i.e; BREAK DOWN OF THESE
MACHINES WILL NOT AFFECT THE
PRODUCTION PROCESS
CAUSES OF BREAKDOWN:
I. FAILURE TO REPLACE THE WORNOUT PARTS
II. NON APPLICATION OF LUBRICANTS
III. NEGLECTED COOLING SYSTEM
IV. CARELESSNESS TOWARDS MINOR REPAIRS.
2.PREVENTIVE MAINTENANCE
 AIMED AT AVOIDING OR PREVENTING
BREAKDOWNS.
 THE PRINCIPLE OF PREVENTIVE MAINTENANCE
IS ‘PREVENTION IS BETTER THAN CURE’
 HERE SOME COMPONENTS ARE IDENTIFIED AS
WEAK SPOTS IN ALL MACHINERIES AND
EQUIPMENTS.
 THESE PARTS ARE INSPECTED REGULARLY.
 MINORS REPAIRS ARE CARRIED OUT
IMMEDIATELY AS SOON AS THERE IS NECESSITY
AVOIDING UNANTICIPATED BREAKDOWNS.
2A. PERIODIC MAINTENANCE ( TIME BASED MAINTENANCE - TBM) 

 Time based maintenance consists of

periodically inspecting, servicing and
cleaning equipment and replacing parts to
prevent sudden failure and process
problems.
2B. PREDICTIVE MAINTENANCE
  
This is a method in which the service life of
important part is predicted based on
inspection or diagnosis, in order to use the
parts to the limit of their service life.
Compared to periodic maintenance,
predictive maintenance is condition based
maintenance. It manages trend values, by
measuring and analyzing data about
deterioration and employs a surveillance
system, designed to monitor conditions
through an on-line system.
3.CORRECTIVE MAINTENANCE
 Corrective maintenance can be defined as
a maintenance task performed to identify,
isolate, and rectify a fault so that the
failed equipment, machine, or asset can be
restored to an original condition/
operational condition.
4.PRODCUTIVE MAINTENANCE

 Total productive maintenance (TPM) is a

maintenance philosophy that requires the
total participation of the workforce. TPM
incorporates the skills of all employees and
focuses on improving the overall
effectiveness of the facility by eliminating
the waste of time and resources.
ADVANTAGES OF MAINTENANCE:
 LIFE OF MACHINERY AND EQUIPMENS ARE
INCREASED.
 PRODUCTION TAKES PLACE AS PER THE SCHEDULE.
 PRODUCTS ARE DELIVERED TO CUSTOMERS IN TIME
AND HENCE HIGH LEVEL OF CUSTOMER
SATISFACTION CAN BE EXPECTED.
 MACHINES ARE IN GOOD CONDITION.HENCE
QUALITY OF THE PRODUCTS WILL BE GOOD.
 NO PRODUCTION LOSS.
 MACHINERY IS NOT DAMAGED.
 NO IDLE TIME OF MEN AND MACHINES.HENCE THEIR
UTILITY INCREASES.
মেইন্টেন্যন্স উপকারিতা:

 মেশিনের জীবন যাত্রা বাড়ে

 প্রডাকশন যথাসময়ে সম্পন্ন হয়
 প্রোডাক্টের গুনগত মান ভাল থাকে
 প্রডাকশন লস কমে যায়
 প্রডাক্টিভিটি বাড়ে
 প্রোডাক্টের কাস্টমার গ্রহণযোগ্যতা বাড়ে
DISADVANTAGES OF POOR
MAINTENANCE:
 MACHINERY MAY BE DAMAGED.THIS IS A LOSS.
 POORLY MAINTAINED MACHINES WILL
PRODUCE POOR QUALITY PRODUCTS.
 MORE WASTAGE OF MATERIALS.
 BREAK DOWN OF MACHINES MAKES BOTH MEN
AND MACHINE IN IDLE POSTION.SO
PRODUCTION TIME IS WASTED.THIS WILL
INCREASE COST OF PRODUCTION.
 POOR MAINTENACE CAUSE ACCIDENTS.
 DUE TO POOR MAINTENACE LIFE OF MACHINE
IS REDUCED.
Maintenance Cost
All enterprises and organizations are interested in lowering
maintenance costs. A very common delusion is that

THE PRODUCT GIVES THE INCOME

MAINTENANCE COSTS MONEY

PROBLEMS IN MAINTENANCE
 Lack of management attention to
maintenance
 Little participation by accounting in
analyzing and reporting costs
 Difficulties in applying quantitative
analysis
 Difficulties in obtaining time and cost
estimates for maintenance works
 Difficulties in measuring performance
মেইন্টেন্যন্স কাজের অসুবিধাঃ

১। ব্যবস্থাপনাবর্গের মনোযোগ কম থাকে

২। মেইন্টেন্যন্স কাজে প্রয়োজনীয় সময় দেয়া হয়না
৩। সংখাত্তক পর্যালোচনা(quantative analysis)করা
কঠিন
৪। Performance analysis করা কঠিন
 Contd…
MAINTENANCE WICH IS NOT CARRIED OUT ,WILL COST EVEN
MORE THAN MONEY !!!!!!
 EXAMPLE
 If we don't replace bearing certain time like
1 year. It may causes motor burnt out that
involves more cost, like bearing cost, cost of
wire, manpower cost, productivity &
reputation lost(due to machine breakdown
unable to deliver product demand on time)
 But if we did replace bearing on time it was
involved only bearing cost.
 MAINTENANCE COSTS
Cost

Breakdown Cost

Maintenance
Commitment
 MAINTENANCE COSTS
Cost

PM Cost

Breakdown Cost

Maintenance
Commitment
 MAINTENANCE COSTS
Cost
Total Maintenance Cost

PM Cost

Breakdown Cost

Optimal Maintenance
Commitment
The Basic Maintenance
Cycle
PLANNING

ANALYSIS PERFORMANCE

RECORDING
মেইন্টেন্যন্স চক্রঃ
পরিকল্পনা
করা

বিশ্লেষণ সম্পাদন
করা করা

নথিভু ক্ত
করা
Planning: based on Maintenance
schedule, we have to make a
maintenance plan.

Performance: As per plan, we have

to perform maintenance.

Recording: Maintenance activities

must be recorded.
Analysis: After performing
maintenance & keep record we have
to analysis machine .e.g.
OEE(overall equipment
effectiveness)= Availability x
Performance x Quality
VIDEO ON MAINTENANCE
VIDEO ON TPM
Any Questions ???
Thank you..