MANAGEMENT 1. Explain Overall Purpose of a Maintenance Program Purpose of a Maintenance Program An organisation comprises a group of people who come together to serve the needs of customers by offering them quality products. To produce high quality products, the organisation needs different types of machines and equipment. Thus, machines and equipment form an essential part of an organisations functioning. If machines and equipment are not under good condition, it would create hindrances in the production process. This, in turn, would affect the other department of an organisation, such as sales, marketing, and customer support, by making unnecessary delays in delivery. Therefore, to keep these machines and equipment functional, maintenance is required.
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2. Explain different types of maintenance tasks.
Types of maintenance tasks The type and range of acceptance are as below:
maintenance
tasks
that
are
gaining
wide
Level Level Level Level Level
1: 2: 3: 4: 5:
Design-out and design-in maintenance
Servicing task On-condition based maintenance Scheduled maintenance On (operate to) failure
Level 1: Design-out and design-in maintenance: In design-out
maintenance, the main cause of failure is determined and rectified so that it can be prevented in the future. Design-out
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3. Explain following Aspects to be Considered for
Machine Quality Conformance to machine specifications Frequency of machine failures Answer: Conformance to machine specifications Machine specifications are the detailed and precise description of what is expected from a machine or equipment. These specifications include the details of design, dimensions, operations, performance, material used, description of installation along with the brand and model number of a machine or equipment. Machine specifications should be precise, accurate, and objectively stated. This is because any
inaccuracy in machine specifications may lead to ineffective maintenance
resulting into huge cost and various accidents. Properly
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4. What do you mean by Condition Monitoring?
Elaborate various Steps Involved in Condition Monitoring Program Condition Monitoring To sustain in todays highly competitive business environment, every organisation has to produce goods as per customer requirements. For this, it is important for organisations to ensure a smooth production process. To keep the production process uninterrupted, organisations must check that machines and equipment are available as and when required for production. If machines are not available on time, organisations may have to face long downtime due to abrupt failures, which may lead to increased production costs and delays in product delivery. In order to keep the machines available, it is essential to
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5. a. b. c. d.
Write short notes on the followinga.
Zero based budgeting Remote maintenance audit Codification of spare parts Maintenance Benchmarking
a. Zero based budgeting
Zero based budgeting: It is a method of budgeting in which all expenditures are justified each time a budget is prepared for a new period. Zero based budgeting begins with a zero base. Each function within the organisation is evaluated in terms of cost and requirements for the coming fiscal year. Budgets are later prepared on the basis of the evaluation regardless of whether the budget is higher or lower than the previous period. In simple terms, the zero based budgeting approach does not depend on historical data and justifies all expenditures on the basis of the requirement and availability of resources. Let us understand this with the help of an example. Assume that the marketing department of Company XYZ spent ` 80,00,000 on its operations the last year. For the
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6. Describe maintenance.
various
types
of
preventive
Types of Preventive Maintenance
Preventive maintenance aims to retain machines and equipment under good working conditions and avoid failures through early detection. It differs across organisations depending on their plant size and other requirements. However, preventive maintenance is broadly classified into four types, which are shown in below figure:
Let us discuss different types of preventive maintenance in detail.
Time-based preventive maintenance: In this type of preventive maintenance, maintenance work is performed at regular time intervals (for example, weekly, monthly, quarterly, and annually, etc.). Time-based maintenance schedules are prepared on the basis of time
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