CE-DD Capacity Strengthening Program

Self-Learning Session-2

ENHANCING ORGANIZATION'S
ABILITY TO REALIZE ITS MISSION,
SERVE ITS CONSTITUENCY
SESSION-2 P R E S E N T E D B Y ME L K A M MI K R U
 Workshop Equipment
Maintenance Management
Course

March 8, 2024
Objective

• To provide maintenance management

knowledge and skills to persons selected from
rehabilitation centres who will be core staff
member for the development of maintenance
management and care of orthopedic
workshop assets.
Session Outcome

By the end of the session, participant should be able to:

• Identify parts and components of power tools and machines,

• Understand how power tools and machineries are functioning,
• Understand the importance and types of maintenance,
• Carryout maintenance and basic repair of orthopedic workshop
machineries and power tools,
• Organizing machineries and tools file and maintaining records,
• Organizing spare part inventory.
 Introduction to Maintenance Management

Maintenance Management :
Is concerned with planning, organizing and
directing resources in order to sustain
maximum efficiency of manufacturing
equipments and facilities.
 Introduction to Maintenance Management

Maintenance & Repair

• Repair is restoration of an asset when it is
not functional due to damaged or
breakdown,

• Maintenance refers to routine activities

that sustain functionality and prevent
damage of asset.
 Introduction to Maintenance Management

Objectives:
• Minimizing the production downtime that
incurs cost to service providers and clients,
• Maximizing useful life of equipments ,
• Sustain products quality,
• Ensure workshop staff safety,
• Contributes to fulfill organizational mission,
• Proper utilization of budget.
 Introduction to Maintenance Management
Type of Maintenance
• Preventive maintenance
• Predictive/condition maintenance
• Breakdown maintenance (repair)
Area of Maintenance
• Civil
• Mechanical
• Electrical
 Introduction to Maintenance Management

Preventive maintenance(condition
• It is proactive and cost effective ). approach,
• Is routine maintenance of different equipment
and machinery to ensure smooth operations and
reduce equipment failures,
• It is scheduled activities running while operation
or shutdown.
 Introduction to Maintenance Management

Predictive maintenance(condition)
• Condition-driven preventive mainte nance
program based on direct monitoring of
mechanical condition and system efficiency,
• Maintenance scheduled based on the status of
the equipment or machinery that is predicted in
advance.
 Introduction to Maintenance Management

Breakdown maintenanc(repair)
• Reactive approach; dealing with breakdowns or
problems when they occur,
• Maintenance performed on equipment that has
broken down, faulted, or otherwise cannot be
operated.
• The goal of breakdown-maintenance is to fix
something that has malfunctioned.
 Introduction to Maintenance Management

Organizing Maintenance Program

Our Perception:
• The first step to effective maintenance
management is to see maintenance as an
investment not as expense,
• Every maintenance activity must be seen as an
activity expected to yield financial surplus.
 Introduction to Maintenance Management

Establish Goal:
• Reduced production/service
downtime,
• Reduced costs,
• Increased asset reliability etc..
 Introduction to Maintenance Management

Organize Human Resource:

• Incorporate maintenance team or worker into
organizational job position structure
• Train maintenance staff and operators,
• Set clear communication lines,
• Develop “good care” award to motivate good
performance.
 Introduction to Maintenance Management
Attitude Shift
 Introduction to Maintenance Management
Who Dose What
Operators Maintenance Team
Daily Inspection Time Based Inspection
Daily cleaning Periodic Major cleaning
Daily Lubrication Periodic Maintenance
Record & Communication Organizing Spare Parts &
Consumables
Condition Based Repairs
Planning & Reporting
 Introduction to Maintenance Management

Standardize Procedures:
• Setup Operational & Maintenance Manual
• Develop standard maintenance procedure,
• Develop preventive maintenance checklist.
 Introduction to Maintenance Management

Plan & Budget

• Maintenance activities &schedule for each asset,
• Annual spare parts requirements,
• Annual consumables requirements ,
• Outsource tasks & services.
 Introduction to Maintenance Management

Asses the status of equipments

• Open file for each important equipments,
• Organize operational manuals & other documents,
• Record the status of the equipment,
• List and specify essential spare parts.
 Introduction to Maintenance Management

Equipment file shall contain but not limited for

• Summary card
• Operation manual/ instructions
• Warranty certificate ,
• Maintenance log sheet .
 Introduction to Maintenance Management
Summary card shall have the following info.
• Discretion of equipment
• Model & serial number
• Asset registration number
• Total value
• Date of installation
• Location
• Supplier name and address
• Type of accessories
• Person responsible for the equipment
• Annual asset inventory remarks
 Introduction to Maintenance Management

Checklist shall keep the following records

• Name and asset registration number,

• Description of time based maintenance tasks,
• Date of maintenance performed,
• Next maintenance schedule date,
• Remarks,
• Name and signature of person who performed the tasks,
• Name and signature of person checked & approved.
 Introduction to Maintenance Management

Organize Tools & Consumables:

• Stock spare parts Inventory,
• Organize maintenance and safety tools,
• Stock lubricant and cleaning materials.
 Introduction to Maintenance Management

Reporting:
• Periodical activity reports & revised plan,
• Spare parts & consumables used,
• Direct costs of maintenance
• Labour
• Material
• Overhead
 Introduction to Maintenance Management

Anticipated Challenges
• Management commitment,
• Attitude of equipment users /operators
• Opening a new job position,
• Budget shortage,
• Absence of after sales services & local supply of
spare parts ,
 Group Assignment -1-
Participants, using the data you brought from your Centres
discuss and identify gaps on the following maintenance
management issues and present your findings.

1. Human Resource
2. Manuals & Procedures,
3. Planning & Reporting
4. Inventory of spare parts and consumables,
5. Record keeping.
 Group Assignment-2-
Participants, taking in to account the above briefing
and discussion, exercise drafting the following
formats:
– Maintenance checklist
– Equipment summary card
•Thank You for Your
Attention.