JJ616 Maintenance Management

Engr. Dr. Choong Chee Guan

Class: DKM 6D

09 January 2015

TEST 1
Section A: Short Essay Questions
CLO1
To point out the concepts of maintenance organization and strategies that increases productivity by
increasing availability and capacity at reduced cost. (C4)
CLO2
To relate the principles of maintenance strategies and elaborate on the significance of a system approach to
maintenance. (C6)
PLO 1
CLO
1, 2

QUESTION 1
i)
Discuss the needs for maintenance.
[2 marks]
ii)

List THREE (3) objectives of maintenance engineering.

[3 marks]

iii)

The types of maintenance cost are shown in the figure below.

Elaborate the relationship between preventive maintenance cost and breakdown cost as shown.
[15 marks]

PLO 1
CLO 1,
2

QUESTION 2
i)
Define the following terms:a) Preventive maintenance
c) Predictive maintenance
e) Overhaul

b)
d)

Corrective maintenance
Reliability
[5 marks]

ii)

List TEN (10) functions of a maintenance department.

[10 marks]

iii)

Differentiate between Reliability Centered Maintenance (RCM) and Traditional Maintenance

Practices applied in a maintenance organization.
[5 marks]

Section B: Short Case Study

PLO 6
CLO 3

CLO3
To organize maintenance management plan and schedule that integrates the whole management processes
and procedures by group in actual workplace. (A4)

QUESTION 3
By referring to an indenture diagram of a car system, study the different maintenance strategies that can be
applied for different levels of the car system.
[40 marks]

JJ616 Maintenance Management

Engr. Dr. Choong Chee Guan
Class: DKM 6D

09 January 2015

TEST 1
CLO1
Point out the concepts of maintenance organization and strategies that increases productivity by increasing
availability and capacity at reduced cost. (C4)
CLO2
Relate the principles of maintenance strategies and elaborate on the significance of a system approach to
maintenance. (C6)

Question 1
i)

Discuss the needs for maintenance.

Answers:Since the Industrial Revolution, maintenance of engineering equipment in the field has been a
challenge. Although impressive progress has been made in maintaining equipment in the field in an
effective manner, maintenance of equipment is still a challenge due to factors such as size, cost,
complexity, and competition. Needless to say, todays maintenance practices are market driven, in
particular for the manufacturing and process industry, service suppliers, and so on.
An event may present an immediate environmental, performance, or safety implication. Thus, there
is a definite need for effective asset management and maintenance practices that will positively
influence critical success factors such as safety, product quality, the speed of innovation, price,
profitability, and reliable delivery.
ii)

List THREE (3) objectives of maintenance engineering.

Answers:The contributing objectives of maintenance engineering include: improve maintenance operations

reduce the amount and frequency of maintenance
reduce the effect of complexity
reduce the maintenance skills required
reduce the amount of supply support
establish optimum frequency and extent of preventive maintenance to be carried out
improve and ensure maximum utilization of maintenance facilities
improve maintenance organization.
(* choose any three of the above given answers)
iii)

Maintenance is a cost and to a customer really adds no value to a product.

Maintenance Costs include: the salaries maintenance staff, cost of inventories kept for the
maintenance procedures such as spares for machines, tools & equipment and cost of
outsourced maintenance activities.

On the other hand Failure Costs include: cost of idle production employees during the lost
time when equipment is down for repairs, production losses during breakdown taking into
consideration upstream and bottleneck equipment can be costly if it means the shutdown of
the whole plant, cost of penalties or damages claimed by the customer
The frequency of maintenance must be balanced with the cost if a failure should occur.
In some instances, it might be less costly to run a machine until it breaks down, and then to
perform the necessary emergency repairs.
The relationship between the maintenance costs and the cost of failures is illustrated in the
figure shown. The curve illustrates that there is an optimum level when preventive
maintenance programs should be carried out when Cost of Maintenance and Cost of
Breakdown are EQUAL.
Question 2
i)

Define the following terms:a)

b)
c)
d)
e)

Preventive maintenance
Corrective maintenance
Predictive maintenance
Reliability
Overhaul

Answers:a)

Preventive maintenance
All actions carried out on a planned, periodic, and specific schedule to keep an
item/equipment in stated working condition through the process of checking and
reconditioning. These actions are precautionary steps undertaken to forestall or lower the
probability of failures or an unacceptable level of degradation in later service, rather than
correcting them after they occur.

b)

Corrective maintenance
The unscheduled maintenance or repair to return items/equipment to a defined state and
carried out because maintenance persons or users perceived deficiencies or failures.

c)

Predictive maintenance
The use of modern measurement and signal processing methods to accurately diagnose
item/equipment condition during operation.

d)

Reliability
The probability that an item will perform its stated function satisfactorily for the desired period
when used per the specified conditions.

e)

Overhaul:
A comprehensive inspection and restoration of an item or a piece of equipment to an
acceptable level at a durability time or usage limit.

ii)

List TEN (10) functions of a maintenance department.

Answers:-

A maintenance department is to perform a wide range of functions including:

Planning and repairing equipment/facilities to acceptable standards.

Performing preventive maintenance; more specifically, developing and implementing a
regularly scheduled work program for the purpose of maintaining satisfactory
equipment/facility operation as well as preventing major problems.
Preparing realistic budgets that detail maintenance personnel and material needs.
Managing inventory to ensure that parts/materials necessary to conduct maintenance tasks
are readily available.
Keeping records on equipment, services, etc.
Developing effective approaches to monitor the activities of maintenance staff.
Developing effective techniques for keeping operations personnel, upper-level management,
and other concerned groups aware of maintenance activities.
Training maintenance staff and other concerned individuals to improve their skills and
perform effectively.
Reviewing plans for new facilities, installation of new equipment, etc.
Implementing methods to improve workplace safety and developing safety education-related
programs for maintenance staff.
Developing contract specifications and inspecting work performed by contractors to ensure
compliance with contractual requirements.

(* choose any ten of the above given answers)

iii)

Differentiate between Reliability Centered Maintenance (RCM) and Traditional Maintenance

Practices applied in a maintenance organization.

Answers:Reliability Centered Maintenance (RCM) integrates preventive maintenance, predictive maintenance

and proactive maintenance to increase the probability that a machine or component will function in
the required manner over its design life-cycle with a minimum amount of maintenance and
downtime.
The advantages of Reliability Centered Maintenance (RCM) are: Can be the most efficient maintenance program.
Lower costs by eliminating unnecessary maintenance or overhauls.
Minimize frequency of overhauls.
Reduced probability of sudden equipment failures.
Able to focus maintenance activities on critical components.
Increased component reliability.
Incorporates root cause analysis.
(* choose any four of the above given answers)
Traditional Maintenance Practices such as reactive maintenance (i.e. breakdown) is a too common
practice that is inherently wasteful and ineffective with disadvantages: No warning of failure.
Possible safety risk.
Unscheduled downtime of machinery.
Production loss or delay.

 Possible secondary damage.

(* choose any four of the above given answers)