Introduction to Maintenance

Prof. Neelakantam Tatikonda

profneelakantam@gmail.com
Imagine

 MAS flight Boeing 737 left KLIA at 2:00 pm

 All two engines, hydraulic systems working
 2:22 pm explosion shook plane
 Number 2 engine torn apart, 2 separate
hydraulic lines ceased to work
 In spite of maintenance work, engine still
failed
 Imagine having no maintenance system
 Maintenance and reliability is important
 Maintenance and product quality
 Maintenance and productivity
 Maintenance and safety
 Maintenance and supply chain, JIT
 Failure cause disruption, waste,
accident, inconvenience and expensive
 Operators less able to do repairs
themselves
 Machine and product failure can have
effect on company’s operation and
profitability
 Idle workers, facility
 Losses due to breakdown
Definition:

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:
 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
Importance:

 Dependability of service
 Assured quality
 Prevent equipment failure
 Cost control
 Huge investment in equipment
Failure
 Failure – inability to produce work in
appropriate manner
 Equipment / machine failure on production
floor – worn out bearing, pump, pressure
leaks, broken shaft, overheated machine etc.
 Equipment failure in office – failure of power
supply, air-conditioned system, computer
network, photocopy machine
 Vehicle failure – brake, transmission, engine,
cooling system
Maintenance in Service
Industry
 Hospital
 Restaurants
 Transport companies
 Banks
 Hotels and resorts
 Shopping malls / retail
 Gas station
Maintenance in Manufacturing
Companies
 Electronic
 Automotive
 Petrochemicals
 Refinery
 Furniture
 Ceramics
 Food and beverages
Purpose of Maintenance

 Attempt to maximize performance of

production equipment efficiently and
regularly
 Prevent breakdown or failures
 Minimize production loss from failures
 Increase reliability of the operating
systems
Problems in Maintenance

 Lack of management attention to

maintenance
 Little participation by accounting in analyzing
and reporting costs
 Difficulties in applying quantitative analysis
 Difficulties in obtaining time and cost
estimates for maintenance works
 Difficulties in measuring performance
Problems Exist Due To:
 Failure to develop written objectives and
policy
 Inadequate budgetary control
 Inadequate control procedures for work order,
service requests etc.
 Infrequent use of standards
 To control maintenance work
 Absence of cost reports to aid maintenance
planning and control system
Maintenance Costs

 Cost to replace or repair

 Losses of output
 Delayed shipment
 Scrap and rework
 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.
 ORGANISATION MAY USE ANY OR ALL
THE FIVE TYPES OF MAINTENANCE

 Breakdown maintenance or corrective

maintenance
 Preventive maintenance
 Predictive maintenance
 Routine maintenance
 Planned maintenance
BREAKDOWN MAINTENANCE

 Occurs when there is a work stoppage

due to machine breakdown
 Maintenance becomes repair work
 Seeks to get the equipment back into
operation as quickly as possible
 To control the investment in
replacement spare machines.
Preventive management

It is undertaken before the need arises

and aims to minimize the possibility of un
-anticipated production interruption or
major breakdowns.
 Predictive maintenance:
In this, sensitive intruments(eg.vibration
analysers,amplitude meters,audio
gauges,optical tooling and resistance
gauges) are used to predict trouble.
Conditions can be measured on a
continuous basis and this enables the
maintenance people to plan for an
overhaul.
 Routine maintenance: this includes
activities such as periodic
inspection,cleaning,lubrication and
repair of production equipments after
their service life.
 Planned maintenance: it involves the
inspection of all plant and
equipments,machinery,buildings
according to a predetermined schedule
in order to service overhaul, lubricate or
repair, before actual break down or
deterioration in service occurs.
CONTROL OF MAINTENANCE

1. Authorized by an official
2. Maintenance schedule
3. Issue materials against proper
authorization
4. Maintenance budgets
5. Equipment records
 Issues:
 how much maintenance is needed?
 What size maintenance crews must be
used?
 Can maintenance be sub-contracted?
 Should maintenance staff be covered
by wage incentive schemes?
 Can effective use be made of
computers for analyzing and
scheduling activities?
Preventive Maintenance:

Preventive maintenance is undertaken

before the need arises and aims to
minimize the possibility of un-
anticipated production interruptions or
major breakdowns.
It consists of:

 Proper design and installation of

equipment
 Periodic inspection of plant and other
equipments
 Repetitive servicing and overhaul of
equipment
 Adequate lubrication, cleaning and
painting
Benefits:

 Greater Safety
 Decreased Production Down Time
 Fewer large Scale & Repetitive Repairs
 Less Cost for Simple Repairs
 Less Standby Equipment Required
 Better Spare parts Control
 Proper Identification f Items
 Maintenance Scheduling:
Scheduling refers to timing and
sequences of operations.

It is an important segment of the

production planning & control activity
as well as the service operations like
plant maintenance
 Importance of scheduling:
 Facilitates optimum use of highly paid
maintenance staff

 Equipments can be utilized effectively

 Eliminates undue interruptions in the

production flow
 Eliminates chances of sudden
breakdown

 Facilitates proper sequence in

maintenance service
Reliability:

 Component Reliability

 Product Reliability
Component Reliability

Definition:

 It is the probability that a part or a

component will not fail in a given time
period or number of trails under ordinary
conditions of use.
 MEASUREMENT
 Component reliability is usually measured by
reliability, failure rates and mean time between
failures, i.e.

CR=1-FR
number of failures
Where FR = number of components
tested

number of failures
FRn = unit-hrs of operation of the
component

1 unit-hr of operation
MTBF = FRn = No. of failures
 PRODUCT RELIABILITY OR
SYSTEM RELIABILITY

 When components or parts are combined into

a larger system, such as a machine or a
product, the combined reliability of all the
components or parts form the basis for product
or system reliability
 CALCULATION OF
PRODUCT OR SYSTEM
RELAIBILITY
 When critical components interact
during the operation of the product or
system, the reliability of the product or
system is determined by computing the
product of the reliabilities of all the
interacting critical components.
SR = CR1*CR2*…..*CRn
 TURN OUT A RELIABLE
PRODUCT
FIVE KEY AREAS
 Design of the product
 Production
 Measurement and testing
 Maintenance and
 Field of operation.
 Conclusion:
 To ensure effective implementation of
activities, it is important that the
production facilities need to be
maintained in good working condition.
 Reduces cost, machinery breakdown etc
 Quality assurance

Therefore maintenance management is

an important aspect for any organisation