Topic 1

Introduction to Maintenance

Aim s

Maintenance goal
Terothecnology
Importance of Planned Maintenance
Maintenance and Support costs
Changing world of maintenance
Challenges facing maintenance
Basic Maintenance concept

What is Maintenance?

Maintenance is not merely preventive

maintenance, although this aspect is an
important ingredient.
Maintenance is not lubrication, although
lubrication is one of its function.
Nor is maintenance simply a frantic rush to repair
a broken machine parts or building segment,
although this can sometimes be a dominant
maintenance activity.

Maintenance
The term MAINTENANCE,
covers all activities undertaken to keep
equipment in a particular condition or return
it to such condition.

Maintenance Management
means
The management of maintenance
It indicates a comprehensive
management, from planning to their
maintenance.

Modern maintenance management is not

to repair broken equipment rapidly
BUT
Modern maintenance management is to
keep the equipment running at high
capacity and produce quality products
at the lowest cost possible

Maintenance Goal

The goal of any well-run maintenance

organization is to have the lowest cost of
the sum of two quantities, i.e.:
Maintenance labour and material: and
Production loss (which includes lack of ability
to produce, and value added material that is
lost as a result of a break down) reduction
resulting from an inadequate maintenance
program

Terotechnology
Definition:
A combination of management,
financial, engineering and other
practices applied to physical assets in
pursuit of economic life cycle costs. Life
Cycle Costing (LCC) involves collecting
all the cost information incurred during
plant life

Terotechnology system
Typical contributions include:

Design - assets designed for

maintainability and reliability
Procurement - application of 'best buy'
procurement techniques
Projects - provision of assets having
operability and maintainability features

Terotechnology

system (cont.)

Operations - introduction of operating

techniques which reduce downtime and
improve care of assets
Finance - cost control, cost monitoring
and feedback
Personnel - selection and training
programmes for operating and
maintenance personnel

Importance of Planned
Maintenance
Equipment is subject to deterioration, causing
malfunction and breakdown with the effects:
Reducing productive capability by reducing
output due to downtime
Increasing operating cost
Interfering customer service
Affects to maintain product quality standards
Has serious safety and environment
consequence

Maintenance and Support

costs

Loss of production or service

Maintenance personnel
Education and training
Replacement
Repair parts
Spares
Consumables

Maintenance and Support costs

(cont.)

Workshop installation
Facilities
Tools and test equipment
Planning system
Programs
Manuals & documentation
Inventory costs
Pack, handle, store and transport

Changing world of
maintenance

Growing expectations of
maintenance
Changing views on
equipment failure
New maintenance
techniques

Challenges facing
maintenance

To select the most appropriate techniques

To deal with each type of failure process.
To fulfill all the expectations of the owners of
the assets, the users of the assets and of
society as a whole
In the most cost-effective and enduring fashion
With the active support and co-operation of all
the people involved

Effective management of
maintenance function

Ensure equipment be available to

function efficiently when needed
Consistent with safety of people and
plant
Contribute to the production and profit
objectives

Basic Maintenance Concept

Any actions carried out to retain an item
in,
or restore
it to, an acceptable condition

(1) Service: the supply of necessary machine

service and support

Lubricate
Inspect
Adjust, calibrate, align, rig
Replace
Repair
Cleaning
Remove
Install

(1) Service: the supply of necessary machine

service and support (cont.)

Functional test
Preserve or de-preserve
Fault isolation
Handling

(2) Logistic: the supply of materials, spares

and personnel for service and
maintenance.
(3) Maintenance strategy planning: the
selection of maintenance and repair
strategies to minimize life cycle cost.
(4) Failure analysis: for design and reliability
improvement