Ce diaporama a bien été signalé.
Le téléchargement de votre SlideShare est en cours. ×


Prochain SlideShare
Chargement dans…3

Consultez-les par la suite

1 sur 45 Publicité

Plus De Contenu Connexe




  1. 1. MAINTENANCE MANAGEMENT BY Dr. C. MANIKANDAN Words Maintaining Relationship Activities Maintaining Honesty 2/6/2023 1
  2. 2. 2/6/2023 2 UNIT-1:MANITENANCE CONCEPTS Objectives and Functions of Maintenance – Maintenance Strategies – Organisation for Maintenance – Five Zero Concepts.
  3. 3. MAINTENANCE •Maintenance are the set of activities performed to keep an equipment in the specified condition or it is remedial action to restore the equipment to its specified condition. Maintenance can be improved by enlarging repair crews, by increasing repair capabilities and providing more inventory of replacement items. 2/6/2023 3
  4. 4. Need or Purpose of Maintenance »To avoid sudden break-down in plant »To improve the life of the machine »To enrich production capacity »To increase the utilization of the plant equipments 2/6/2023 4
  5. 5. Significance of Maintenance • MM is a supporting activity to effective operation • Able to maintain quality standards • High quantity and low cost of product • MM determine; »The risk-safety »Environmental integrity »Energy efficiency »Product quality »Customer service profile of the organization 2/6/2023 5
  6. 6. OBJECTIVES of MM  Maintaining system capability.  Minimizing total costs.  Prevent unexpected breakdowns.  Reducing shutdown Periods.  Ensuring maximum plant availability.  Maintenance of equipment and its rated productivity and original accuracy  Elimination of unsafe conditions that cause accidents thereby ensuring safety of workmen  Minimization of wear and tear to increase the equipment life. 2/6/2023 6
  7. 7. Reasons for Breakdown in a Plant Excessive friction between the parts. Failure to replace parts that are known to wear. Neglected cooling system. Neglected common minor faults. Overloading of machines, wrong fuel, obstruction of air intakes, faults in another items of equipment. Design or manufacturing defects of the equipment Installation deficiencies. Improper handling of the machines by the operators. 2/6/2023 7
  8. 8. A formal definition of maintenance is that function of manufacturing management that is concerned with day to day problem of keeping the physical plant in good operating condition. Objectives of MMS Minimize loss of productive time Minimize repair time cost Keep productive assets in working condition Minimize accidents Minimize total maintenance cost Improve quality of products 2/6/2023 8
  9. 9. Maintenance Importance Dependability of service Assured quality Prevent Equipment Failure Cost control Huge investment in equipment 2/6/2023 9
  10. 10. Areas of Maintenance 1. Civil Maintenance- Building construction and maintenance, maintaining service facilities. 2. Mechanical Maintenance- Maintaining machines and equipments, transport vehicles, compressors and furnaces. 3.Electrical Maintenance- Maintaining electrical equipments such as generators, transformer, motors, telephone systems, lighting, fans, etc. 2/6/2023 10
  11. 11. Impact of Maintenance Production Capacity Production Cost Product and service Quality  Employee or Customer Safety Customer Satisfaction Organization Losses 2/6/2023 11
  12. 12. Problems in MM •Lack of mgt attention on MM •Inadequate budget for M works •Difficulties in applying quantitative analysis. • Failure to maintain documents related to MM. •Inadequate use of Standards •Absence in maintenance planning. 2/6/2023 12
  13. 13. Functions of Maintenance 1. It maximize overall efficiency 2. It increases worker efficiency 3. It verifies effectiveness of the major corrective works. 4. It motivates operators by involving them in maintenance. 5. It minimize indirect cost . 6. It reduces the product cost. 7. It improves working safety. 8. It enhances improvement in process. 9. It maximize plant capacity. 10.It maintain customer satisfaction. 2/6/2023 13
  14. 14. ORGANISATION MAY USE ANY OR ALL THE FIVE TYPES OF MAINTENANCE  Breakdown maintenance or corrective maintenance Preventive maintenance Predictive maintenance Routine maintenance Planned maintenance 2/6/2023 14
  15. 15. Elements of Maintenance 1. MANAGEMENT COMMITMENT Formation of quality Mgt Setting up and service on a quality committee Providing resources and training Overseeing implementation at all levels of the organization Evaluating and revising the policy in light of results achieved. 2/6/2023 15
  16. 16. Elements of Maintenance 2. Budget: An Estimate of costs, Revenues and Resources over a specified period , reflects the future financial conditions and achievements. 3. Planning and Scheduling:  Every preventive maintenance work should be preplanned on the basis of previous records. The planned programme should be monitored effectively. The attention on maintenance programme at the period of Daily, Weekly, Monthly, half-yearly and Yearly. 2/6/2023 16
  17. 17. 4. Authority • Reference to Maintenance Management. • To role as a decision maker regarding maintenance activities. 5.Ability: • Knowledge about the Maintenance. • Handling different Equipments and Tools. 6. Training : • Sound training is essential. • Maintenance team should trained with proper technical knowledge. • Inspection and repairs in a systematic approach. 2/6/2023 17
  18. 18. 7.Record Keeping » Operation manual , Maintenance instruction manual. » Spares procurement register. » History cards and history register. » Inspection register. » Log books. » Defects register. 2/6/2023 18
  19. 19. Need For Maintain Maintenance Records • To prevent Defects rather than rectifying after break-downs. • To know about the machines reliability and thus helps in production planning. • To decide the Life of the machines. • To forecasting Defects and planning to rectify them before the failure occurs. • To carryout the inspection frequently. • To decide the New one to purchase. 2/6/2023 19
  20. 20. Elements of Maintenance 8. Facilities Inspection: » Keeping spares » Proper space allocation for machine » Scheduled » To avoid breakdown 9. Maintenance Audit: » Design » Assurance » Functions » Product quality/ quantity » Customer feed back 10. Management Review: » Review » 1/4 yearly » ½ yearly 2/6/2023 20
  21. 21. Advantages of Maintenance 1. Minimize the Production Cost. 2.Minimize the Repair time and Repair cost. 3.Minimize the loss due to production stoppage. 4. Effective utilization of man and machines. 5.Prolonging life of capital assets by minimizing the rate of wear and tear. 6.Maximizing efficiency and economy in production through optimum use of facilitates. 7.Avoid the accidents by periodical inspection and repair. 8.Minimize the total maintenance cost. 9.Maintain all production resources in better conditions. 10.Improve quality , quantity and customer satisfaction. 2/6/2023 21
  22. 22. Requirements for Good Maintenance • For achieving maintenance of high order, following are some of the essential requirements:  Good supervision and Administration of maintenance department.  Proper control of work, priority is fixed wit care and after consultation with Engineering Production and departments.  Truthful , Clear and detailed instructions are given to the maintenance team and to the operators.  Operators should be trained.  A good lubrication programme should be chalked out.  Proper maintenance record should be maintained.  Adequate stock of spares should always be kept.  Cleanliness with adequate lighting and ventilation.  Manufactures of the machine tools should be consulted as and when required.  Co-ordination with other departments. 2/6/2023 22
  23. 23. Maintenance strategies • Breakdown Maintenance • Preventive Maintenance • Predictive maintenance • Proactive maintenance 2/6/2023 23
  24. 24. Types of Maintenance strategy Maintenance Strategy Maintenance Approach Significance Break down maintenance Fix-it breakdown occurs Low maintenance cost Preventive maintenance Scheduled maintenance Periodic component replacement Predictive maintenance Condition based monitoring Maintenance decision based on equipment condition Proactive maintenance Detection of source of failures Monitoring and correcting failing root causes 2/6/2023 24
  25. 25. Break down Maintenance or Corrective Maintenance • Corrective maintenance may be defined as the repairs carried out to restore equipment, which had broken down or developed a fault, so as to restore a failed system to operational status. • Causes of breakdown: »Inadequate maintenance »Insufficient maintenance »Workplace hazards »Inadequate coverage of equipments 2/6/2023 25
  26. 26. Breakdown Maintenance Procedure • BDM carried out in three steps: • Diagnosis of the problem. • Repair and / or replacement of failure components. • Verification of the repair action. • Goals and objectives. 2/6/2023 26
  27. 27. Advantages and Dis- advantages of BDM • Advantages: »Down time is less »Non-critical costs are minimum »Repair costs are less • Disadvantages: • Breakdown occurs inappropriate time •Delay in production •Direct loss of profit •Excessive delay in production and output. •Faster industry deterioration …….. Etc. 2/6/2023 27
  28. 28. Preventive Maintenance • Preventive maintenance strategy can be very expensive. • In India most of the industries follow the breakdown maintenance. • Preventive maintenance is essential as per the factory law (ex: Boiler) 2/6/2023 28
  29. 29. Preventive Maintenance -Definition • Preventive maintenance may be defined as a set of systematic inspection procedures and maintenance activities carried out to keep the equipment in the optimum operating state, minimize the faults and prevent breakdowns. • It is a time based maintenance strategy. • Based on visual inspection , the fault on the machines are rectified and machine back to its working position. 2/6/2023 29
  30. 30. Objectives of Preventive Maintenance • To produce and supply the components to the customer with optimal cost. • To improve productivity. • To lead the life cycle of the machine tools. • To maintain plant safety. • To develop well checked out and systematic inspection procedures and maintenance activities. • To minimize the machine down time. 2/6/2023 30
  31. 31. Preventive Maintenance Procedure ( Stitch –in-time procedure) 1. Maintaining Machine Records: Type of equipment and description. Name of the manufacture. Cost and date purchase. Breakdown if any and their dates and reasons. List of spare parts and their code numbers. 2. Preparing Inspection Check List:  Material handling equipments.  Safety equipments.  Process equipments.  Water , fuel and air lines. Key equipments and machineries. 2/6/2023 31
  32. 32. Frequency of inspection depends upon: i. Severity of utilization of machines. ii. Age , condition and value of the equipment. iii. Safety and health environment. iv. Amount of exposure to drift , fumes, friction , fatigue ,stress and corrosion wear etc. 3. Inspection as per check list and corrective action:  Routine up – keep adjustment of guide plates, lubrication and cleaning.  Periodic inspection.  Preventive maintenance should carried out without disturbing the production. 2/6/2023 32
  33. 33. Advantages of Preventive Maintenance • Reduces the breakdown maintenance. • Low maintenance and repair costs. • Less stand- by equipments and spare parts. • Better product quality and fewer reworks and scraps. • Increase plant life. • Reduce pre-mature wear and tear. • Provide regular and prescribed inspection and service schedule. • Production disturbance is less. 2/6/2023 33
  34. 34. Dis-advantages of Preventive Maintenance • Exposes equipment to possible damage. • Failure in new parts. • Use more parts. • Increase initial costs. • Requires more frequent access to equipment. 2/6/2023 34
  35. 35. Predictive Maintenance • The aim of predictive maintenance is two-fold. First: To predict when the equipment failure might occur. Second: To prevent occurrence of failure by performing any required maintenance. Purpose: it is allow convenient scheduling of corrective maintenance and to prevent unexpected equipment failures. 2/6/2023 35
  36. 36. Predictive Maintenance • Advantages • Increased equipment lifetime, plant safety, • Fewer accidents and optimized spare parts handling. • Applications • Critical operational function • Failure modes can be cost effectively predicted with regular monitoring 2/6/2023 36
  37. 37. • Concentrate on the monitoring and correction of root causes of equipment failures. • Extend the useful age of the equipment to reach the wear out stage by adapting a high mastery level of operating precision. • Proactive Maintenance Consists of: • Preventive Maintenance and • Predictive Maintenance. Proactive Maintenance 2/6/2023 37
  38. 38. • It consists of preventive and predictive maintenance. • Use of improved maintenance tools such as Reliability Centered Maintenance (RCM), Root Cause Failure Analysis, etc. Proactive Maintenance 2/6/2023 38
  39. 39. Proactive Maintenance • Advantages 1. Ability to prolong the life of machinery. 2.Prevent an unexpected breakdown of production. 3. Allows an organization to schedule production shutdowns for repairs, inspection and maintenance. 2/6/2023 39
  40. 40. Proactive Maintenance 1. Focus is now not only concentrated on availability but also reliability. 2. There is a push towards zero downtime or zero- in-service break downs. 3. Use of improved maintenance tools: Reliability Centre Maintenance (RCM) Root Cause Failure Analysis ( RCFA) 2/6/2023 40
  41. 41. Maintenance Organisation • Need of Maintenance Organization: • Role of maintenance organization: – Optimum availability of machineries and other systems. – Optimum operating conditions. – Maximum utilization of resources. – Optimize equipment life. – Minimize the spares inventory. 2/6/2023 41
  42. 42. •Objectives of Maintenance Organization Size of the maintenance force for different organizations.( small, medium and large plant) Training to the maintenance persons. Ensuring safety of personnel and equipment. Identification of obsolete and surplus equipment for replacement and disposal. 2/6/2023 42
  43. 43. FIVE ZERO CONCEPT • Zero Breakdowns • Zero Accidents • Zero Defects • Zero waste • Zero Inventory 2/6/2023 43
  44. 44. To achieve five zero concepts the following practices are necessary • To maximize over all efficiency of the plant. • To make continuous improvement and reduce production cost. • To enrich all personalities with knowledge. • To develop environmental friendly. • T foster a harmonious work culture. 2/6/2023 44
  45. 45. THANK YOU • REFERENCES: • Mishra R.C and Pathak K ,Maintenance Engineering and Management, PHI, 2nd Edition, 2012. • R. Keith Mobley, Maintenance Fundamentals, 2nd Edition, Butterworth Heinemann Publications, 2011. 2/6/2023 45