MAINTENANCE MANAGEMENT

ASSIGNMENT No 1

Q1) what should be the objectives of maintenance management for successful working
of the maintenance department.

Solution-1

Objectives of Maintenance Management

The following are some of the objectives of maintenance management:

I. Minimizing the loss of productive time because of equipment failure (i.e. minimizing idle time
of equipment due to break down).
II. minimizing the repair time and repair cost.

III. Minimizing the loss due to production stoppages.

IV. Efficient use of maintenance personnel and equipments.

V. Prolonging the life of capital assets by minimizing the rate of wear and tear.

VI. To keep all productive assets in good working conditions.

VII. To maximize efficiency and economy in production through optimum use of facilities.

VIII. To minimize accidents through regular inspection and repair of safety devices.

IX. To minimize the total maintenance cost which includes the cost of repair, cost of preventive
maintenance and inventory carrying costs, due to spare parts inventory.

X. To improve the quality of products and to improve productivity.

 Q2) Show the classification of maintenance system.

Corrective maintenance: The set of tasks is destined to correct the defects to

be found in the different equipment and that are communicated to the maintenance
department by users of the same equipment.

Preventive Maintenance: Its mission is to maintain a level of certain service on

equipment, programming the interventions of their vulnerabilities in the most
opportune time. It is used to be a systematic character, that is, the equipment is
inspected even if it has not given any symptoms of having a problem.

Predictive Maintenance: It pursues constantly know and report the status and
operational capacity of the installations by knowing the values of certain variables,
which represent such state and operational ability. To apply this maintenance, it is
necessary to identify physical variables (temperature, vibration, power consumption,
etc.). This maintenance it is the most technical, since it requires advanced technical
resources, and at times of strong mathematical, physical and / or technical knowledge.

Zero Hours Maintenance (Overhaul): The set of tasks whose goal is to review
the equipment at scheduled intervals before appearing any failure, either when the
reliability of the equipment has decreased considerably so it is risky to make forecasts
of production capacity . This review is based on leaving the equipment to zero hours of
operation, that is, as if the equipment were new. These reviews will replace or repair
all items subject to wear. The aim is to ensure, with high probability, a good working
time fixed in advance.

Periodic maintenance (Time Based Maintenance TBM): the basic

maintenance of equipment made by the users of it. It consists of a series of
elementary tasks (data collections, visual inspections, cleaning, lubrication,
retightening screws,) for which no extensive training is necessary, but perhaps only a
brief training. This type of maintenance is the based on TPM (Total Productive
Maintenance).
Q3) A company has machine whose cost is Rs 30000/-. Its maintenance cost and resale
value at end of different years are as given below. At what time interval in your opinion
should the machine be replaced?

Year I II III IV V VI
Maintenance 4500 4700 5000 5500 6500 7500
Cost
Resale Value 27000 25300 24000 21000 18000 1300

Solution-3

End of Resale Capital operating total average

year value loss cost cumulative cost cost cost
E=SUBMISSIO
A B C D ND F=C+E G=F/A
1 27000 3000 4500 4500 7500 7500
2 25300 4700 4700 9200 13900 6950
6733.33333
3 24000 6000 5000 14200 20200 3
4 21000 9000 5500 19700 28700 7175
5 18000 12000 6500 26200 38200 7640
6 1300 28700 7500 33700 62400 10400
Q4) Following mortality rates have been observed for certain types of fuses. There are
1,000 fuses in use and it costs Rs 5/ to replace an individual fuse. If all fuses where
replaced simultaneously it would cost Rs1.25/- .it is proposed to replace all fuses at fixed
interval of time whether or not they have burnt out and to continue replacing burnt out
fuses as they fail. At what intervals the group replacement should be made and what is
the optimum policy

Week 1 2 3 4 5
% of failing by 5 15 35 75 100
The end of week

SOLUNTION-4

The total no. of fuses are 1000.

Let Pi be the percentage of the failure during ith week

Cost of individual replacement per week-

P1 = 0.05

P2 = 0.15 0.05 = 0.10

P3 = 0.35 0.15 = 0.20

P4= 0.75 0.35 = 0.40

P5 = 1 0.75 = 0.25

Average life of a resistor = submission i x Pi

Average life = 1 x 0.05 + 2 x 0.10 + 3 x 0.20 + 4 x 0.40 + 5 x 0.25

= 3.7 weeks

Average no. of failure per week = 1000 / 3.7

= 270.27 = 271

Cost of replacement = average no. of failure per week x cost of single resistor
 = 271 x 5

= 1355 Rs

Cost of group replacement

N0 = 1000

N1 = 1000 x 0.05 = 50

N2 = 1000 x 0.10 + 50 x 0.50 = 125

N3 = 1000 x 0.20 + 50 x 0.10 + 125 x 0.05 = 211.25

N4 = 1000 x 0.40 + 50 x 0.20 + 125 x 0.10 + 211.25 x 0.05 = 433.06

N5 = 1000 x 0.25 + 50 x 0.40 + 125 x 0.20 + 211.25 x 0.10 + 433.06 x 0.05 = 337.77

end of group replacement individual total average

week cost cost cost cost
1 1250 250 1500 1500
2 1250 625 1875 937.5
3 1250 1060 2310 770
4 1250 2170 3420 855
5 1250 1690 2940 588

Optimum replacement policy is group replacement at the end of 3rd week and replacement of
resistors individually during those 3 weeks.