MAINTENANCE

ENGINEERING
INTRODUCTION
Syllabus
UNIT – I PRINCIPLES AND PRACTICES OF MAINTENANCE PLANNING

UNIT II – MAINTENANCE POLICIES – PREVENTIVE MAINTENANCE

UNIT III – CONDITION MONITORING

UNIT IV – REPAIR METHODS FOR BASIC MACHINE ELEMENTS

UNIT V – REPAIR METHODS FOR MATERIAL HANDLING EQUIPMENTS

MAINTENANCE - DEFINITION
Maintenance is the routine and recurring process of keeping a
particular machine or equipment or asset in its normal operating
condition so that it can deliver the expected performance or
service without any loss or damage.

The responsibility of the maintenance function is to ensure that

the production equipment or facility is available for use for
maximum time at minimum cost within the stipulated time
period.
????
Can we use and throw machines?

Do we invest in maintenance to run a machine?

Example : Steel plant
Blast furnace , Rolling milling

What decides?
Capital cost and criticality
How do we maintain machines / Equipments?

PREVENTIVE MAINTENANCE (Periodic )

PREDICTIVE MAINTENANCE – (Condition)
BREAKDOWN MAINTENANCE – (Reactive)

Preventive maintenance
Regularly follow a schedule of maintenance
Time interval is fixed
No matter the machine is good or bad
Ex : Defence
Based on time span, Classification of Maintenance
Programme
Hourly : Lubricant level, Sharpness of tool, etc.,

Daily: Cleaning of machines, tightening of nuts, minor

adjustments of parts, etc,

Weekly: Major adjustments, lubricant topping, etc,

Monthly: Corrosion
PREDICTIVE MAINTENANCE
CONDITION BASED MAINTENANCE

PREDICTING THE CONDITION OF MACHINE / EQUIPMENT

SIGNALS SIGNALS OF HUMAN BODY

Visual ECG
Tactile BODY TEMPERATURE
Electrical BLOOD PRESSURE
Vibration – 70 %
Temperature
Wear Debris Analysis – 20 %
NDT – 10 %
DIAGNOSTICS – To Know the defects

PROGNOSIS – Remaining Useful Life

PREDICTIVE MAINTENANCE MANAGEMENT

It is a philosophy that uses the actual operating condition of the equipment and
systems to optimize total plant operation.

Predictive maintenance is a condition driven preventive maintenance program

Assumptions that the machines will degrade

Sometimes unnecessary repairs made

Downtime can be controlled

RELIABILITY CENTERED MAINTENANCE (RCM)
Investigation of failure modes to determine best maintenance strategy

Chooses right approach for right piece of equipment

1. Establishing Criticality levels

2. Identify FMEA
3. Apply RCM
MAINTENANCE

ENGINEERING
UNIT-I
PRINCIPLES AND PRACTICES
OF MAINTENANCE PLANNING
CO1 Describe objectives and the basic principles in maintenance

CO2 Explain Maintenance Policies and Preventive Maintenance

CO3 Illustrate the various processes involved in condition monitoring

CO4 Explain the influence of failure analysis in basic machine elements

CO5 Explain the role of Repair Methods for Material.

• Basic Principles of maintenance planning
• Objectives and principles of planned
maintenance activity
• Importance and benefits of sound
Maintenance systems
• Reliability and Machine availability
• MTBF, MTTR and MWT
• Factors of availability
• Maintenance organization
• Maintenance economics.
Maintenance engineering : Maintenance engineering is
the activity of applying engineering concepts to the
optimization of equipment, procedure and departmental
budgets to achieve better maintainability, reliability and
availability of equipment.

Planning: Planning ensures the smooth operation of the

system. Planning defines what is to be done and how it is to
be done. It specifies the materials, tool, equipment and
skills required to perform the work.
Main classification of planning in engineering system are as follows,
1. Long range planning
2. Short range planning
3. Planning for immediate activity

4.Long Range planning : For a period of five years at least. Involves capital
budgeting, strategies and operational programmers.

5. Short range: up to one year. Made to achieve short term goals.

6. Immediate Activity Planning : it is done frequently whenever required.

Objectives of Planned Maintenance Activity

 To achieve minimum breakdown and to keep the plant in good working condition at the lowest
possible cost.
 To ensure the availability of machines and services in an optimum working condition.
 To keep machines and other facilities in a condition to be used to achieve the maximum profit without
any interruption.
 To keep the time schedule of delivery to customers.
 To meet the availability requirements for critical equipment.
 To keep the maintenance costs as low as possible for non-critical equipment.
 To control the effective and trained supervision.
 To meet the quality requirements of the product.
 To increase the profits of production systems.
Principles of Maintenance :They are followed in a system to guide the staff to
work efficiently and effectively to achieve the overall objectives of the
maintenance system,

Main areas of work governed by this principles are

 Plant management in Maintenance work
 Production and maintenance objectives
 Establishment of work order and recording system
 Information based Decision making
 Adherence to planned maintenance strategy .
 Manpower for Maintenance
 Planning for maintenance functions
 Role of Spare parts
 Training.
 SOUND MAINTENANCE SYSTEM
The following are the benefits of sound maintenance management system
 Minimization of down time
 Improvement in availability of system
 Extended life of equipment
 Safety and smooth operation of the process
 Providing adequate back up supply
 Minimization of normal expected wear and tear of equipment
 Safety of the personal involved in the organization
 Increasing the reliability of the system
 Providing a proper working environment
 Cost effective maintenance boosts the profit of the production system.
Reliability: Reliability is the probability that a component/system when
operating under given condition will perform its intended functions adequately
for a specified period of time.
RELIABILIT
Y

Inherent Reliability Achievable Reliability

It is associated with the quality of the Its depends on maintenance and
material and design of machine operation of the equipment
parts
Inherent Reliability
It is associated with the quality of the material and design of
machine parts

Achievable Reliability
It depends on other factors such as maintenance and operation of
the equipment.

The total reliability of any equipment is a

function of design, maintenance and field operational reliability
AVAILABILITY
Availability is the ratio of time at which the equipment is available for
the designated operation or service to the total time of operation and
maintenance of the equipment

It is also defined as ratio of equipment’s uptime to the equipment’s

uptime and downtime over the specified period of time.
Inherent Availability
Inherent Availability is the probability that a system or
equipment shall operate satisfactorily when used under prescribed
conditions in an ideal support environment without any scheduled or
preventive maintenance at any given time.

Inherent Availability = MTBF/(MTBF + MTTR)

Ideal support means the ready availability of tools, spare parts,

manpower, manuals, etc.,
Achieved Availability
Achieved availability is the probability that a system or equipment shall
operate satisfactorily when used under prescribed conditions in an ideal
support environment with periodic preventive and corrective maintenance
at any given time.

Achieved availability = MTBM / (MTBM+M)

Where M is the mean active maintenance downtime resulting from

preventive and corrective maintenance
OPERATIONAL AVAILABILITY
Operational availability is the probability that a system or equipment shall
operate satisfactorily when used under prescribed conditions in an actual supply
environment without any scheduled or preventive maintenance at any given time.

Operational availability = MTBM / (MTBM + MDT)

Where MDT is the mean down time, is the statistical mean of the downtimes
including the supply downtime and administrative downtime.

Availability of a system is a complex function of reliability , maintainability and supply

effectiveness
Maintainability

Maintainabiity is defined as the probability that a unit or system

will be restored to specified working conditions within a given period
when maintenance action is taken in accordance with the prescribed
procedures and resources
Equipment lifecycle: Reliability engineering is dependability in the life cycle management of
product. The failure pattern of equipment over its life cycle can be represented as bath-tub curve.
MACHINE AVAILABILITY =UPTIME /(UPTIME + DOWNTIME)
 Mean Time To Failure(MTTF):Mean Time To Failure (MTTF) is a very basic measure of reliability
used for non-repairable systems. It represents the length of time that an item is expected to last in
operation until it fails.
Mean Time Between Failures(MTBF): The term MTBF is used for repairable systems, but it does not
take into account units that are shut down for routine scheduled maintenance
 Mean Time To Repair (MTTR):It refers to the amount of time required to repair a system and
restore it to full functionality. The MTTR clock starts ticking when the repairs start and it goes on
until operations are restored. This includes repair time, testing period, and return to the normal
operating condition.
A Maintenance organization consists of three basic and necessary components
Resources
Administration
Work Planning and Control system

RESOURCES
Resources include men, spares and tools involved in the task of maintenance.

ADMINISTRATION
Administration includes a hierarchy of authority and responsibility for making
decisions and plans the execution of the work.

WORK PLANNING AND CONTROL SYSTEM

It is a mechanism for planning and scheduling the work. This also includes the
feedback of information to drive the maintenance effort to its defined objective.
TASKS OF MAINTENANCE ORGANIZATION
Identification of organization roles pertaining to maintenance function

Determination of maintenance workload.

Uniform distribution of total maintenance work to all the personal in the department

Identification and assignment of essential works to the various sections of the maintenance
department

Proper knowledge about the technical expertise / experience of the workers deputed for the
particular job

Proper training of the staff of maintenance to meet the growing demands of the industry and to
catch up with the modern trends in maintenance

Designing the policies and procedures at an early stage to help the maintenance department to
achieve the goals of the industry
MAINTENANCE FUNCTIONS AND ACTIVITIES

Identifying areas for implementation of Preventive maintenance program

Making suitable arrangements for maintenance facilities for carrying out the maintenance work
properly

Planning and Scheduling the total maintenance work

Ensuring proper and timely supply of spare parts

Managing proper inventory control of materials spares and tools required for the maintenance

Standardization of maintenance work

Implementing modifications to the existing equipment wherever possible

MAINTENANCE FUNCTIONS AND ACTIVITIES

Assisting the Purchase department in procuring materials , Disbursement of services such as water,
electricity, steam, compressed air and other amenities required to carryout the maintenance

Identification of obsolete and surplus equipment for replacement and disposal

Designing the systematic way for disposal of equipment and for maintaining floor space

Training of maintenance personnel

Analysis of future demands and forecast the role of maintenance activities

Implementation of safety norms and procedures

Ensuring safety of personnel and equipments

TYPES OF MAINTENANCE ORGANIZATION
The selection of a type of maintenance system will largely depend on the structure of
an industry.

Maintenance organization can be broadly classified into three types as follows

DECENTRALIZED

• suitable for large sized plants where inter unit communication is difficult to get.
• In this type of organization, the maintenance is under the control of chief
engineer of production to ensure better understanding between the production
and maintenance department
CENTRALIZED
• suitable for small units where unit communication is feasible.
• In this type of organization, the maintenance is under the control of chief
maintenance engineer.
• The responsibilities and accountability is with the concerned department heads.

PARTIALLY CENTRALIZED

• A modified version of centralized maintenance organization and suitable for the

industry where units are located at far away locations.
• In this type of organization, the maintenance personal attached with production
unit will carryout the routine maintenance works
• Scheduled maintenance works such as overhauls, planned maintenance work,
procurement of spare parts are under the control of chief management
engineer at the central office
The Basic Two types of organizations followed in most of the industries are

LINE ORGANIZATION
LINE STAFF ORGANIZATION
• CENTRALLY CONTROLLED MAINTENANCE ORGANIZATION

MAINTENANCE SUPERINTENDENT

MAINTENANCE ENGINEER

General Foreman General Foreman General Foreman Planning supervisor General

Foreman
Mechanical Service shop Electrical Fabrication shop

All the major types of maintenance work are undertaken by central workshop.
The limitation is it is possible only for equipments which can be shifted to workshop
• AREA MAINTENANCE ORGANIZATION

AREA CHIEF ENGINEER

Area production engineer Area Administration Officer Area Maintenance Engineer

Mechanical Engineer

Lubrication Engineer

Instrumentation Engineer

Maintenance Documentation Engineer

Workshop superintendent
Area Maintenance Organization provides better utility of manpower when the
units are located at various locations

Example MINING INDUSTRY

Area maintenance manager takes care of maintenance for a particular area and
is equipped with number of workers to carry out maintenance work including
emergency work
In case of Major important maintenance works, this team will coordinate with
central workshop.
General Organization Structure of Maintenance Department
GENERAL ORGANIZATION OF MAINTENANCE DEPARTMENT
EXTERNAL MAINTENANCE SERVICES

External maintenance services are available in two forms :

Contract Maintenance services and
Manufacturers after sale services
Advantages
It is very economical
Technically better and specialist are responsible for maintenance activities
Skill preservation
Better service
Updating to modern and existing trends and needs
OUTSOURCING IN MAINTENANCE
To ensure maximum control over the maintenance activities, it is followed in large
industries
ADVANTAGES
Cost of maintenance is minimized

No need for having maintenance as a department

Better quality of service achieved through employing specialists

Better maintenance practices

Performance metrics are clearly defined and achieved by outsourcing the

maintenance jobs
LIFE CYCLE COST ANALYSIS

Life cycle costing is the cost analysis for the equipment in an industry that
accounts the total cost of the equipment over a period of time which
includes the capital cost, operating costs and maintenance costs.

This analysis is the integration of engineering, economic and financial

strategies in relation to the equipment to be purchased.

To ascertain the total cost of the equipment over the span of its entire life
period
ADVANTAGES OF LIFE CYCLE COSTING

Integration of engineering, economics and financial aspects lead to the

way of robust metric for the selection and purchase of equipment
required for the industry.

Reduced operating and maintenance cost of equipments due to cost

analysis over span of time

It leads to the selection of proper and economically viable equipment

Maintenance economics: Life-cycle
cost analysis (LCCA) is a tool to
determine the most cost-
option among different effective
competing
alternatives to purchase, own, operate,
maintain and, finally, dispose of an
object or process, when each is equally
appropriate to be implemented on
technical grounds

Estimation of economic life of

equipment: its depends on
the cost, availability
maintenance and repair
and operational efficiency.
Reliability costs :Reliability
costs are the business costs of
unreliable systems.

Maintenance costs :Maintenance

costs are the cost of doing
maintenance; be that reactive or
preventive maintenance.