Intro To Maintenance

Maintenance
Maintenance
management is the routine

and recurring process of keeping a
particular machine or asset in its normal
operating condition so that it can deliver its
expected performance or service without
causing any loss of time on account of
accidental damage or breakdown.
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
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
Problems Exist Due To:
Failure to develop written objectives and

policy
Inadequate budgetary control
Inadequate control procedures for work order,
service requests etc.
Infrequent use of standards
To control maintenance work
Absence of cost reports to aid maintenance
planning and control system
Maintenance Objectives
Must
be consistent with the goals of

production (cost, quality, delivery,
safety)
Must be comprehensive and include
specific responsibilities
Maintenance Costs
Cost
to replace or repair
Losses of output
Delayed shipment
Scrap and rework
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) maintenance
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
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
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 regulated by
statutory provisions e.g. cranes, lift and hoists etc
Scheduled Maintenance
Scheduled maintenance is a stitch-in-time

procedure and incorporates
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.
Preventive Maintenance (PM)

Principle
Prevention is better than cure

Procedure - Stitch-in-time
It
locates weak spots of machinery and equipments
provides them periodic/scheduled inspections and
minor repairs to reduce the danger of
unanticipated breakdowns
Candidates for Preventive

Maintenance
Frequency of Failure
Good candidates
have more normal
distribution with
low variability
Mean Time Between Failure (MTBF)
Advantages of PM
Advantages:
Reduces break down and thereby down time

Lass 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
Increases chances to get production incentive
bonus
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.
Predictive Maintenance (Contd.)

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
Maintenance Costs
Cost
Breakdown Cost
Maintenance
Commitment
Maintenance Costs
Cost
PM Cost
Breakdown Cost
Maintenance
Commitment
Maintenance Costs
Cost
Total Maintenance Cost
PM Cost
Breakdown Cost
Maintenance
Commitment
Maintenance Costs
Cost
Total Maintenance Cost
PM Cost
Breakdown Cost
Optimal
Maintenance
Commitment
Determining the Size of Repair Crews
Problem:
A factory has 200 machines and the maintenance
engineer supervises the repair crews who repair
malfunctioning machines. The maintenance policy is
to repair the broken down machine and bring back in
production within 2 hours on the average. If average
breakdown rate is 3.5 machines/hour and each repair
crew can repair 0.25 machine per hour on the
average. How many repair crews are required ?
Solution
The formula for average repair rate () is
1
ts = ---------- or
= + 1/ ts
-
Where = repair rate
= arrival rate of malfunctioning machines
ts = average time arrivals in the system
Required average repair rate
= 3.5 + 1 / 2 = 4 machines / hour
No. of Crews = machines/hour a crew can repair
= 4 0.25 = 16 repair crews required

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Intro To Maintenance

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Maintenance

management is the routine

To achieve product quality and customer

Lack of management attention to

Problems Exist Due To:

Failure to develop written objectives and

be consistent with the goals of

Maintenance may be classified into four categories:

Corrective or Breakdown maintenance

Quite justified in small factories where:

Breakdown generally occurs inappropriate times

Scheduled maintenance is a stitch-in-time

Preventive Maintenance (PM)

Prevention is better than cure

Candidates for Preventive

Mean Time Between Failure (MTBF)

Reduces break down and thereby down time

predictive maintenance, machinery conditions

makes use of human sense and other

Predictive Maintenance (Contd.)

sounds coming out of a rotating

Total Maintenance Cost

Total Maintenance Cost

Determining the Size of Repair Crews

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