MAINTENANCE

Maintenance Aspect and Conceptual Approach

Presented By:
Ashok Kumar Shawlecha
 Maintenance Definition
• Maintenance is a set of organised activities that are carried out in
order to keep an item in its best operational condition with
minimum cost acquired.
• Activities of maintenance function could be either repair or
replacement activities, which are necessary for an item to reach its
acceptable productivity condition and these activities, should be
carried out with a minimum possible cost.
 Maintenance Objectives
• Maximising production or increasing facilities availability at the
lowest cost and at the highest quality and safety standards.
• Reducing breakdowns and emergency shutdowns.
• Optimising resources utilisation.
• Reducing downtime.
• Improving spares stock control.
• Avoid surprise failures.
• Improving equipment efficiency and reducing scrap rate.
• Minimising energy usage.
• Optimising the useful life of equipment.
• Providing reliable cost and budgetary control.
• Identifying and implementing cost reductions
 Types of Maintenance

• Breakdown Maintenance: Unplanned

• Running Maintenance : Planned
• Preventive Maintenance : Planned
• Predictive / Proactive Maintenance : Planned
 Key Element of Maintenance
• Primary elements in he Maintenance function
are to be responsive, manageable, measurable
and accountable. Maintenance will be
“Proactive” and “Predictive” in nature.
• Maintenance will be managed using sound
business principles.
• Maintenance actions will enhance the
company's competitiveness and profitability
Conceptual Approach – Breakdown Maintenance

Definition of Breakdown:
Surprise failure of equipment or not performing for the intended purpose.

Breakdown Maintenance:
* Rushing of Right Person.
* Discussion with problem raiser.
* Checking the unhealthy condition.
* Investigation of issue.
* Analysis of findings.
* Inclusion of findings in Preventive Maintenance.
* OJT for the operator and engineer involve to avoid surprise failure.
Conceptual Approach – Running Maintenance
Definition of Running Maintenance :
Taken care of Running line issues observed or reported in operation
when cell is Idle.

Running Maintenance:
* Rushing of Dedicated and Scheduled Person.
* Work on the feed back or pointed running issues.
* Record in the log book.
* Do verification of immediate supervisor or machine in charge.
* Any observation of running maintenance which need to attend
in next PM plan, must report and record.
* Observation for the issue if repeated again.
Conceptual Approach – Preventive Maintenance
Definition of Preventive Maintenance :
To keep the machine or restore the machine as good as original condition.

Preventive Maintenance:
* Follow the PM Plan.
* Populate the all required tools, check sheet and competent
person with clear guideline of Do’s and Don'ts.
* Verify the past breakdown details or any Comment for PM.
* Perform the CLIT activity.
* After performing the PM activity conduct the machine trial.
* After satisfactory trial, feed the details of findings in record /
Respective Check sheet.
* Register the spare used in PM and plan for spares w.r.t.
Consumption pattern and inventory level.
Conceptual Approach – Predictive / Proactive Maintenance

Definition of Predictive / Proactive Maintenance :

To monitor the machine on best practices to avoid any major failure which
can be predicted and proactively attended while shut down or PM schedule.

Predictive / Proactive Maintenance:

* Use the feed back or record available for machine health.
* Check the availability of spares planed w.r.t. monitoring record.
* Replace or repair as per Monitoring Instructions.
* Take trial and record for next life of failure.
Open Discussion & Questionnaire Session

Please float your feed back, question, share

knowledge in this session.

Thanks