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Plant maintenance

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About Plant Maintenance

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Plant maintenance

  2. 2. Plant maintenance ▶ Maintenance is defined as that function of production management concerned with the day to day problem of keeping the physical plant in good operating condition. ▶ Plant maintenance usually refers to the methods, strategies, and practices used to keep an industrial factory running efficiently. This can include anything from regular checks of equipment to make sure they are functioning properly, to cleaning garbage bins and toilets. The general aim of plant maintenance is to create a productive working environment that is also safe for workers.
  3. 3. Plant maintenance is concerned with actions taken by the plant user to maintain an existing system and facilities or to restore it to an operating condition.
  4. 4. Objectives and Importance?
  5. 5. Objectives ▶ Maintenance of plant, building, machinery and equipments plays an important part in determining the life expectancy of physical assets. The actual service lives may be lengthened considerably by a good maintenance programme.
  6. 6. Purpose The purpose of plant maintenance is usually secondary, however to the need for keeping industrial building and their equipment and good working order. Therefore, the objectives of maintenance are twofold: a) To keep the plant in working conditions. b) To arrest depreciation and forestall obsolescence.
  7. 7. Quote “Maintenance in the industrial plant is the upkeep, repair, renewal and replacement of worn, damaged or obsolete parts of building, machinery and equipments.”
  8. 8. Prevention ▶ Maintenance may be preventive. Preventive maintenance implies frequent inspection to detect minor faults and the early correction of them, so that the possibility of a major breakdown is almost entirely eliminated. ▶ Corrective maintenance implies that action is taken only when the need for it becomes obvious and, therefore, gives no assurance that a major breakdown will not occur.
  9. 9. Continue.. ▶ Most plants use both types of maintenance, where a major defect in one of the building, or in a vital machine, would be seriously reduced or completely stop production, or preventive maintenance program is indicated.
  10. 10. ▶ Since there are many different types of plants and factories, the ways to maintain these facilities often vary. For example, a steel mill will have different machinery than a food processing plant. This means that each place of business generally has its own maintenance plan, tailored to its particularities. A maintenance plan can include scheduling times for equipment checkups, trouble-shooting, and general clean-up.
  11. 11. Continue.. ▶Most plants employ their own maintenance staff. This can include workers such as on-site engineers, whose job is to make sure that machines continue to operate effectively. This is an especially important for plants that use equipment designed for assembly lines, since a stoppage of the line can be financially damaging.
  12. 12. Maintainabil ity ▶ Is concerned with those actions taken by a system and facilities during development so that the system or facilities when installed and operated can be maintained with ease. ▶ Maintainability means design for ease of maintenance. It is the characteristic of system design which determines the ability of a system to be retained in or restored to an effective operational condition. It is concerned with the system’s down time. It include aspects such as: ▶ Incorporation of fail safe features ▶ Tolerance which allows for wear through machine life ▶ Selection of materials that ensure minimum failure due to fatigue and friction
  13. 13. ▶ Reliability is defined as the probability of a plant to give satisfactory performance in a particular period of time under specified conditions. The time between failures is called MTBF ▶ Availability is the percentage of time the machine will be available for operation ▶ Availability = Mean Time Between failures(MTBF) MTBF + Mean Time for Repairs(MTR)
  14. 14. Functions ▶ functions: ▶ Plant protection ( including fire fighting) ▶ Waste disposal ▶ Pollution and noise reduction ▶ Sanitorial services ▶ Storekeeping, accounting etc.
  15. 15. Categories ▶ Breakdown Maintenance ( Corrective maintenance) ▶ Preventive maintenance(PM) ▶ Lubrication & Inspection ▶ Predictive maintenance ( Condition monitoring) ▶ Is a form of PM ▶ by tracing the performance of the machine over its operating life, deterioration that can occur at various intervals of time is predicted. Early symptoms of failure are identified and proper maintenance measures developed.
  16. 16. PM ▶ Is repairing of the machine at planned intervals so that sudden breakdowns could be prevented and costly downtime avoided. This work is generally done when the shop can spare the machine for repairs, generally during off shift hours, Sundays and holidays. ▶ Lubrication and Inspection are two constituents of PM
  17. 17. Advantages of PM ▶ Greater safety to workers ▶ Reduction in production down time ▶ Lesser expenditure on repairs due to fewer repetitive and large scale repairs ▶ Less spare parts ▶ Prolongs the life of the machine ▶ Maintains quality and continuity of production
  18. 18. Disadvantages of PM ▶ High control on records and analysis, planning & scheduling ▶ Monitoring of parameters like temperature, lubrication, noise, corrosion ,leaks etc are high. The equipments to do that also are costly. ▶ Optimum PM is required, hence correct judgement is needed. Too much or too little is not good.
  19. 19. END