MAINTENANC

E
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Introduction to
maintenance
Maintenance and reliability is
important
Maintenance and product quality
Maintenance and productivity
Maintenance and safety
Maintenance and supply chain, JIT
Failure cause disruption, waste,
accident, inconvenience and expensive
Machine and product failure can have
effect on companys operation and
profitability
Losses due to breakdown

Failure

Failure inability to produce work in

appropriate manner
Equipment / machine failure on
production floor worn out bearing,
pump, pressure leaks, broken shaft,
overheated machine etc.
Equipment failure in office failure
of power supply, air-conditioned
system, computer network,
photocopy machine
Vehicle failure brake, transmission,
engine, cooling system
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Maintenance in Service Industry

Hospital
Restaurants
Transport companies
Banks
Hotels and resorts
Shopping malls / retail
Gas station

Maintenance in Manufacturing
Companies

Electronic
Automotive
Petrochemicals
Refinery
Furniture
Ceramics
Food and beverages

Maintenance

All actions necessary for retaining an

item, or restoring to it, a serviceable
condition, include servicing, repair,
modification, overhaul, inspection
and condition verification
Increase availability of a system
Keep systems equipment in working
order

Question?

Why do we need maintenance?

What are the costs of doing
maintenance?
What are the costs of not doing
maintenance?
What are the benefits of
maintenance?
How can maintenance increase
profitability of company?

Purpose of Maintenance

Attempt to maximize performance of

production equipment efficiently and
regularly
Prevent breakdown or failures
Minimize production loss from
failures
Increase reliability of the operating
systems

Principle Objectives in
Maintenance

To achieve product quality and

customer satisfaction through
adjusted and serviced equipment
Maximize useful life of equipment
Keep equipment safe and prevent
safety hazards
Minimize frequency and severity of
interruptions
Maximize production capacity
through high utilization of facility
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Must be consistent with the goals of

production (cost, quality, delivery,
safety)
Must be comprehensive and include
specific responsibilities

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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
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Maintenance Costs

Cost to replace or repair

Losses of output
Delayed shipment
Scrap and rework

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Maintenance Policies that Reduce

Frequency and Severity of Malfunctions
Reduces

Reduces

Maintenance Policy
Frequency
Severity
Emphasize preventive maintenance X X
Provide extra machines X
Replace machine parts early X
Involve operators in maintenance X X
Overdesign machines X
Design machines for maintainability
X
Enhance maint. dept.s capability X X
Increase spare parts supply
X
Increase standby machines
X
Increase in-process inventories
X
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Types of Maintenance

Maintenance may be classified into

four categories:
(some authors prefer three
categories- scheduled and
preventive maintenances are
merged)
Corrective or Breakdown
maintenance
Scheduled maintenance
Preventive maintenance
Predictive (Condition-based)

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1. Corrective or Breakdown
Maintenance

Corrective or Breakdown maintenance

implies that repairs are made after
the equipment is failed and can not
perform its normal function anymore
The unscheduled maintenance or
repair to return items/equipment to a
defined state and carried out because
maintenance
persons
or
users
perceived deficiencies or failures

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Quite justified in small factories

where:
Down times are non-critical and
repair costs are less than other
type of maintenance
Financial
justification
for
scheduling are not felt

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Disadvantages of Corrective
Maintenance

Breakdown
generally
occurs
inappropriate times leading to poor
and hurried maintenance
Excessive
delay
in
production
&
reduces output
Faster plant deterioration
Increases chances of accidents and less
safety for both workers and machines
More spoilt materials
Direct loss of profit
Can not be employed for equipments
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Repair time include

1.
2.
3.
4.
5.
6.

Preparation time
Fault location time
Spare item obtainment time
Fault correction time
Adjustment and calibration time
Checkout time

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Time reduction in corrective

maintenance
1.

2.
3.
4.
5.

Efficiency in fault recognition,

location, and isolation
Effective interchangeability
Redundancy
Effective accessibility
Human factor considerations

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Types Corrective maintenance

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Types of corrective maintenance

Fail-repair: The failed item is restored to
its operational state.
Salvage: This element of corrective
maintenance is concerned with disposal
of non repairable material and use of
salvaged material from non repairable
equipment/item in the repair, overhaul,
or rebuild programs.
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Rebuild: This is concerned with

restoring an item to a standard as close
as possible to original state in
performance, life expectancy, and
appearance. This is achieved through
complete disassembly, examination of
all components, repair and replacement
of worn/unserviceable parts as per
original specification and
manufacturing tolerances, and
reassembly and testing to original
production guidelines.
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Overhaul: Restoring an item to its total

serviceable state as per maintenance
serviceability
standards,
using
the
inspect and repair only as appropriate
approach.
Servicing: Servicing may be needed
because of the corrective maintenance
action, for example, engine repair can
lead to crankcase refill, welding on, etc.
Another example could be that the
replacement of an air bottle may require
system recharging
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2. Scheduled Maintenance

Scheduled maintenance
inspection
lubrication
repair and overhaul of equipments
If neglected can result in breakdown
Generally followed for:
overhauling of machines
changing of heavy equipment oils
cleaning of water and other tanks
etc.
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3. Preventive Maintenance (PM)

Principle Prevention is better than

cure
All actions carried out on a planned,
periodic, and specific schedule to keep
an item/equipment in stated working
condition through the process of
checking and reconditioning. These
actions
are
precautionary
steps
undertaken to forestall or lower the
probability
of
failures
or
an
unacceptable level of degradation in
later service, rather than correcting
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them after they occur

It locates weak spots of machinery

and equipments
It provides them periodic/scheduled
inspections and minor repairs to
reduce the danger of unanticipated
breakdowns

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PM may be described as the care and

servicing by individuals involved with
maintenance
to
keep
equipment/facilities in satisfactory
operational state by providing for
systematic inspection, detection, and
correction of incipient (beginning to
happen or develop) failures either
prior to their occurrence or prior to
their development into major failure

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Elements of preventive maintenance

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Elements of preventive
maintenance
Inspection: Periodically inspecting materials/items
to determine their serviceability by comparing their
physical, electrical, mechanical, etc., characteristics
(as applicable) to expected standards
Servicing:
Cleaning,
lubricating,
charging,
preservation, etc., of items/materials periodically to
prevent the occurrence of incipient failures

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Calibration: Periodically determining the value of

characteristics of an item by comparison to a
standard; it consists of the comparison of two
instruments, one of which is certied standard with
known accuracy, to detect and adjust any
discrepancy
in
the
accuracy
of
the
material/parameter being compared to the
established standard value
Testing: Periodically testing or checking out to
determine
serviceability
and
detect
electrical/mechanical-related degradation
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Alignment: Making changes to an items specied

variable elements for the purpose of achieving
optimum performance
Adjustment: Periodically adjusting specied
variable elements of material for the purpose of
achieving the optimum system performance
Installation: Periodic replacement of limited-life
items or the items experiencing time cycle or wear
degradation, to maintain the specied system
tolerance
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Advantages of PM

Advantages:
Reduces break down and thereby
down time
Less odd-time repair and reduces
over time of crews
Greater safety of workers
Lower maintenance and repair costs
Less stand-by equipments and spare
parts
Better product quality and fewer
reworks and scraps
Increases plant life

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4. Predictive (Condition-based)
Maintenance

In predictive maintenance, machinery

conditions are periodically monitored
and this enables the maintenance crews
to take timely actions,
such as
machine adjustment, repair or overhaul

It makes use of human sense and other

sensitive instruments, such as
audio
gauge,
vibration
analyzer,
amplitude
meter,
pressure,
temperature and resistance strain
gauges etc.
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Unusual sounds coming out of a

rotating equipment predicts a trouble
An excessively hot electric cable
predicts a trouble
Simple hand touch can point out many
unusual equipment conditions and
thus predicts a trouble

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Maintenance Costs
Cost

Breakdown Cost
Maintenance
Commitment
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Maintenance Costs
Cost

PM Cost
Breakdown Cost
Maintenance
Commitment
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Maintenance Costs
Cost

Total Maintenance Cost

PM Cost
Breakdown Cost
Maintenance
Commitment
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Maintenance Costs
Cost

Total Maintenance Cost

PM Cost
Breakdown Cost
Optimal

Maintenance
Commitment
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