1.
MAINTENANCE
MANAGEMENT
BY
Dr. C. MANIKANDAN
Words Maintaining Relationship
Activities Maintaining Honesty
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UNIT-1:MANITENANCE CONCEPTS
Objectives and Functions of
Maintenance – Maintenance
Strategies – Organisation for
Maintenance – Five Zero
Concepts.

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.
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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
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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
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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.
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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.
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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
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9.
Maintenance Importance
Dependability of service
Assured quality
Prevent Equipment Failure
Cost control
Huge investment in equipment
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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.
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Impact of Maintenance
Production Capacity
Production Cost
Product and service Quality
 Employee or Customer Safety
Customer Satisfaction
Organization Losses
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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.
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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.
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ORGANISATION MAY USE ANY OR ALL THE FIVE
TYPES OF MAINTENANCE
 Breakdown maintenance or
corrective maintenance
Preventive maintenance
Predictive maintenance
Routine maintenance
Planned maintenance
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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.
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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.
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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.
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7.Record Keeping
» Operation manual , Maintenance
instruction manual.
» Spares procurement register.
» History cards and history register.
» Inspection register.
» Log books.
» Defects register.
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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.
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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
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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.
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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.
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23.
Maintenance strategies
• Breakdown Maintenance
• Preventive Maintenance
• Predictive maintenance
• Proactive maintenance
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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
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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
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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.
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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.
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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)
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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
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• 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
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• 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
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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.
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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)
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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.
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•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.
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FIVE ZERO CONCEPT
• Zero Breakdowns
• Zero Accidents
• Zero Defects
• Zero waste
• Zero Inventory
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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.
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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.
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