IE 443: Industrial Safety and

Maintenance

Course In-charge: Dr. Juliana Machuve

Contact: jullymac@udsm.ac.tz
Room: O 106
Department of Mechanical and Industrial Engineering
Topics To be Covered
1. Introduction to Maintenance
Management
2. Failure Analysis
3. Reliability Analysis
4. Maintainability and Availability
Analysis
5. Optimal Replacement Decision
6. Maintenance Strategies
7. Condition Monitoring
Topics To be Covered (Safety and
Health)
1. Introduction to Occupational
Safety and Health
2. Machinery Safety
3. Electrical and Pressure Hazards
4. Hazards at Workplace
5. Fire, Explosions and Hazardous
Materials
Questions
1. What is maintenance?

2. Give 2 examples of areas of maintenance

in your specialization

3. Why do we study maintenance?

 Exchange!
 What is maintenance?
 “to cause to continue in a specific state,
relation or position ...” or “to keep in good
order” or “... the preservation as nearly as
possible of the originally designed and
constructed condition of an object for
purposes of prolonging the life span of the
object”.
What is maintenance? - cont
 According to British Standard BS 3811:1964
maintenance is defined as work undertaken in
order to keep or restore every facility, i.e. every
part of a site, building and contents, to an
acceptable standard.

 Where there are statutory requirements for

maintenance the “acceptable standard” to be
reached must be not less than that necessary to
meet such requirements.
What is maintenance? - cont
 'Maintained' is defined in the Factories Act, 1961
as: ”Maintained in an efficient state, in efficient
working order and in good repair”.

 DIN 31051 maintenance is defined as "actions

for preservation and restoration of the nominal-
condition of a technical system as well as for
substantiating and assessing the real-condition
of the technical system".
 Definition – Maintenance is the:
 “The totality of measures for substantiating,
preservation or restoration of an item or
system to a required condition of that item or
system if necessary.”

 “Activities to check, restore and keep plant

and equipment in the required condition.”
 Classification of Maintenance
 Maintenance can be classified according to the
condition that call for maintenance, or when that
maintenance is carried out.

 The word “when” in this context refers either to “on

what occasion” or “at what time”.

 The classification of maintenance can also be based

on the objectives of doing that maintenance.

 It is the objective of the carrying of maintenance

that defines the maintenance strategy to be used.
Classification of Maintenance. …
cont.
 Basing on “when” maintenance is being
carried out we can consider “failure” as an
occasion or a trigger or an event that is
causing maintenance to be performed.

 If the maintenance is being carried out

before failure then it is known as Preventive
maintenance, but if it is carried out after a
failure it is known Break down maintenance.
Classification of Maintenance. …
cont
 Preventive maintenance has also other names
such as Planned maintenance and Scheduled
maintenance.

 Similarly Break down maintenance has other

names such as Unplanned maintenance,
Unscheduled maintenance.

 .....list other names

Classification of Maintenance. …
cont.
 Preventive maintenance can be classified
as:-
 Regular / Periodic maintenance (based on
specific time interval or after a certain period
of use),
 Condition based maintenance (also known as
Predictive maintenance – depends on the
condition of the facility), as well as
 Opportunity based maintenance.
 Maintenance

Planned Unplanned

Corrective Preventive Opportunity Break down

Periodic (time) Condition Based Periodic (usage)

 Questions
4. Give 2 examples using the classification of
maintenance (based on your area of
specialization)
 E.g Gas leakage in a chemical plant-
Breakdown maintenance (CPE student)

5. Give other names of maintenance and

flowcharts with Classification of maintenance
(HM/ Tutorial)

 Exchange!
 Classification of Work Orders
Planned Periodic
Planned Planned Unplanned Unplanned
preventive work
Type preventive work corrective opportunity Breakdown
order (time
Feature order (Condition maintenance based maintenance
based and usage
based) work orders maintenance work order
based)

Execution
The time is The time is The time is The time is The time is
time of the
planned unplanned planned unplanned unplanned
work order
Content of
the work Known Known Known Known Unknown
order
Cause Specific time Condition of the
(trigger) of interval or run equipment and Impending Condition of
Failure
the work cycles of the impending failure the facility
order equipment failure
Service,
Preventive Preventive
Maintenance preventive Break down Break down
rectification and rectification
actions rectification, and repair repair
inspection and inspection
inspection
 Maintenance Function
 Capacity, but once a rehabilitation is done, then the
capacity can be restored to its original level.
 The capacity and availability of the machine, which
give the production volume, are the functions of
maintenance.
 The first function is to ensure the availability of the
production equipment. A highly maintained
equipment will have a high availability compared to
a less maintained equipment.
 The second function is the restoration of the
capacity. A dilapidated facility will operate at a
reduced capacity.
Production and Maintenance
CAPACITY X AVAILABILITY
PRODUCTION VOLUME

CAPACITY AVAILABILITY

CAPACITY MAINTENANCE
RESTORATION
 Maintenance Objectives
 To ensure availability of the facility in order
meet short term and long term utilisation
targets;

 To preserve the performance of the facility in

order to meet output targets; and

 To ensure that the preventive and corrective

work are balanced to attain optimum trade-off
between direct and indirect maintenance costs.
 GENERAL OBJECTIVES OF A
COMPANY

 To increase production in quality and

quantity.

 To decrease production costs and achieve

optimal balance in technical and economic
lifetime of equipment.
 Maintenance & Company Objectives
 Through a well balanced maintenance of the facility
it is possible to achieve an optimal balance between
technical and economical lifetime of the production
equipment.

 A secret behind achieving the objectives of the

company, such as increased plant safety, increased
lifetime of facilities, decrease of energy use as well
as optimal utilisation of maintenance resources is
hidden in appropriate maintenance management
system.
 Maintenance & Company Objectives

 quantity and quality of products or services

 economical aspects
 organisational aspects
 safety matters
…….others
 COMPANY
OBJECTIVES
MAINTENANCE PLANT OUTPUTS
RESOURCES - Desired operation
- Spare parts patterns
- Information - Desired output level
- Human Resources - Production window

MAINTENANCE
OBJECTIVES
EQUIPMENT LIFE PLANT SAFETY

OTHER PLANT FACTORS

-Efficient energy use
-Clean Production
-Reduction of emissions
Functional division of the industrial
maintenance management
 Maintenance work planning

 Maintenance programming

 Maintenance controlling and

 Maintenance analysis
 Maintenance
Management

Maintenance Maintenance Maintenance Maintenance

Work Planning Programming Controlling Analysis

Maintenance Maintenance Releasing of Work Root Cause

Strategy Planning Program Orders Analysis

Maintenance Maintenance Monitoring of Work Availability

Personnel Planning Schedule & Orders Analysis
Capacity

Maintenance Reliability Analysis

Material Planning Maintenance
Procurements

Maintenance Deviations
Budgeting Analysis

Maintenance Analysis of Weak

Consultation Points
Maintenance Work Planning
 Defined as the deciding in advance the jobs,
methods, materials, tools, machines, labour,
timing and time required.
 The activities of maintenance work planning
include:
 maintenance strategy planning
 personnel planning
 planning of maintenance equipment
 maintenance materials planning
 budgeting for maintenance
 creation of maintenance work orders
 maintenance cost planning
Maintenance Programming
 Defined as a list allocating specific
maintenance task to a specific
period.

 In the maintenance programming the

following tasks are performed:
 planning of maintenance programmes
 maintenance capacity planning
 planning for maintenance schedules
 maintenance procurement
Maintenance Controlling
 deals with the releasing and monitoring of
the maintenance work orders.

 It is the maintenance controlling that:

 scrutinises the availability of the equipment,
 harmonises the distribution of the maintenance
tasks,
 monitors the available capacity and
 collects the data concerning the work orders.
 Maintenance Analysis
 Deals with the identification and analysis of the
weak points, root cause analysis (RCA),
availability analysis, maintainability analysis,
reliability analysis and the analysis of the
deviations in the carrying out of the
maintenance work orders.
 It is based on the results obtained from the
monitoring of the maintenance work orders.
 It is more appropriate in the practise for the
purpose of rectifying the identified weak points.
 Questions
6. Give 2 disadvantages / cons of maintenance

7. Elaborate the linkage between the different

functional divisions of the industrial
maintenance management in a company –
with an example (HM/ Tutorial)

 Exchange!
 Maintenance Terminology:
 Availability
 the proportion of time during which a piece of
equipment is in operational or able to run if
required

 Availability factor is the ratio of Availability to

the period of Maximum requirement

 Operational availability is the probability that

a piece of equipment, when used in actual
operational environment under specified
conditions will operate (i.e. do its job)
satisfactorily when called upon
Maintenance Terminology- Cont
 Utilization factor is the ratio of
Availability to the period of Actual use
 Check is “to compare with an
acceptable standard by suitable or
defined means, whilst the facility is
non-operational”
 Test is “to compare with an acceptable
standard by suitable or defined means,
whilst the facility is operational”
Maintenance Terminology- Cont
 Clean is “to reduce contamination to an
acceptable standard”
 Downtime is the period during which a
facility is not ready for use.
 Facility register is a record of facilities
including information such as
constructional and technical details
about each piece of equipment. This
may be combined with an inventory.
Maintenance Terminology- Cont
 Failure is inability of a component or
part of a piece of equipment to perform
it designed function
 Failure rate is defined as the number of
failures per period of time during which
failure can occur
 Fault report is a document reporting
deviation of a facility from an
acceptable standard
Maintenance Terminology- Cont
 History card is a document on which
information about all work done on and/or by
a particular facility is recorded.
 Inspection refers to "actions for
substantiating and assessing the real-
condition of the technical system”
 Inspection is the process of ensuring by
assessment that a facility reaches the
necessary standard of quality or
performance and that the level is maintained.
 Maintenance Terminology- Cont
 Inventory is a list of all facilities for purposes of
identification.
 Job interval is the period between occurrences
of a particular maintenance job.
 Job report is a statement recording the work
done and the condition of the facility.
 Job card is a document requesting the
maintenance work to be done.
 Job specification is a document describing the
maintenance work to be done.
Maintenance Terminology- Cont
 Maintainability can be defined as the
inherent characteristic of a design or
installation that determines the ease,
economy, safety, and accuracy with which
maintenance actions can be performed.
 Maintenance management is the
organization of maintenance within an
agreed policy.
 Maintenance schedule is a comprehensive
list of maintenance tasks and their incidence.
 Maintenance Terminology- Cont
 Maintenance strategy is the principal function
of planning, whereby the type of maintenance,
the extent of doing and the time of carrying out
of maintenance actions will be established.
 Overhaul is a comprehensive examination and
restoration of a facility, or a major part thereof
to an acceptable standard.
 Permit to work is a signed document,
authorizing access to a facility, which must
define conditions, including safety precautions,
under which work may be carried out.
 Maintenance Terminology- Cont
 Reliability is the probability that a component,
device or system will perform its prescribed duty
without failure for a given time when operated
correctly in a specified environment.
 Repair can be defined as "actions for restoration
of the nominal-condition of a technical system”
 Service - "actions for preservation of a technical
system".
 Service consists of all operative activities aimed
at avoiding or reducing the wear and tear of a
maintenance object.
Maintenance Terminology- Cont
 Work order is a written instruction
detailing work to be carried out.
 Work requisition is a document
requesting work to be carried out.
 Maintenance Resources
 The maintenance resources can be
considered as generating the direct cost of
maintenance. The cost of resources is
relatively easy to measure, using a
maintenance costing system.
 Plant life
 A part of the maintenance resources is necessarily
devoted to ensuring that major plant units and,
indeed, the whole plant itself, survive up to or
beyond the design operating- life. Failures to
ensure this will mean a corresponding loss of the
company’s capital assets.
 The best way of incorporation this into the
objective is “establishing standards of equipment
condition” necessary to see the equipment
through to its expected life.
 Equipment Safety
 One of the functions of maintenance is to ensure
that the equipment is maintained in such a way
that it can be regarded as safe.
 It is difficult to establish measurement for safety
levels in industrial maintenance.
 The usual way is to set ‘safety standards’ based
on the probability of failure occurrence and on
the consequences of a failure.
 (It is also difficult to cost the consequences of a
failure in safety).
 Plant output
 Plant output can be measured via several
parameters.
 The most usual of which is downtime and
the most useful of which output.
 Maintenance Department
 The general objective for the maintenance
department could be defined as:
“To ensure, that the condition of the machinery,
equipment and plant is maintained at such a level
that the requirements of the production
department can be fulfilled”.
 with due consideration to:
 ECONOMY
 SAFETY
 ENVIRONMENT