Maintenance Management

Maintenance
Management
• Maintenance is defined as “ any action that restores failed units to an
operational condition or retains non-failed units in an operational
state.
• Maintenance Management is concerned with the direction and

organization of resources in order to control the availability and
performance of industrial plant to some specific level.
• Objectives of Maintenance:
1. To increase functional reliability of production facilities.

2. To maximize the useful life of the equipment.
3. To maximize production capacity from the given equipment.
4. To minimize the total production cost.
5. To minimize the frequency of interruption in production by reducing
breakdowns.
6. To enhance the safety of the manpower.
• Types of Maintenance:
1. Breakdown (Reactive) Maintenance.
2. Preventive Maintenance.
3. Predictive Maintenance.
• Concept of Reliability in Maintenance:
Reliability is defined as the probability that a product, system, or service will

perform its intended function adequately for a specified period of time, or
will operate in a defined environment without failure.
Thus, reliability means, the capability of a machine or a component to
perform a particular function without breaking down for a specific period of
time under given conditions.
Classification of Reliability:
Reliability can be classified into Component reliability and Product reliability
or System reliability.
Component Reliability: The probability that a type of part or component will
not fail in a given time period or number of trials under ordinary condition
of use.
Product Reliability: When all the components or parts are combined into
larger system such as a machine or product, the combined reliability of all
the components or parts form the basis for product reliability or system
reliability.
• Maintenance Planning:
1. Knowledge base.
2. Job Investigation.
3. Identify and document the work.
4. Development of repair plan.
5. Preparation tools and facilities list.
6. Estimation of time required to do the job.

• Maintenance Scheduling:
• Requirement for Schedulers:

1. Manpower availability.
2. Man hour Backlog.
3. Availability of equipment.
4. Availability of proper tools.
5. Availability of external manpower.
6. Availability of special equipment.

• Maintenance Schedule Techniques:
1. Weekly general schedule.
2. Daily schedule.
3. Gantt charts.
4. Bar charts.
5. PERT/CPM
• Modern Scientific Maintenance Methods:
1. Reliability Centered Maintenance (RCM).
2. Six Sigma Maintenance.
3. Enterprise Asset Management (EAM).
4. Computer Aided Maintenance.
5. Lean Maintenance.
• Reliability Centered Maintenance (RCM):
 Reliability-Centered Maintenance, often known as RCM is a process to

ensure that assets continue to do what their users require in their
present operating context.
 RCM is a maintenance approach that priorities some machines over
others to increase reliability and optimize financial resources.
 It is an industrial improvement approach focused on identifying and
establishing the operational, maintenance and capital improvement
policies that will manage the risks of equipment failure most effectively.
 The primary goal of Reliability-Centered Maintenance (RCM) should
therefore to be insure that the right maintenance activity is performed at
the right time with the right people, and that the equipment is operated
in a way that maximizes its opportunity to achieve a reliability level that
is consistent with the safety, environmental, operational and profit goals
of the organization.
• Six Sigma Maintenance:
 Six Sigma is a set of techniques and tools for process improvement. It

was developed by Motorola in 1986.
 Six sigma seeks to improve the quality of process outputs by identifying
and removing the causes of defects (errors) and minimizing variability in
manufacturing and business processes. It uses a set of quality
management methods, including statistical methods, and creates a
special infrastructure of people within the organization who are experts
in the methods.
 The main methodologies of Six sigma are Define, Measure, Analyze,
Improve, Control (DMAIC) and Design for Six sigma (DFSS).
To apply Six Sigma in maintenance, first find work groups that have a good
understanding of preventive maintenance techniques in addition to a
strong leadership commitment.
• Enterprise Asset Management (EAM):
 Enterprise Asset Management (EAM) is an information management

system that connects to all departments and disciplines within a
company making them an integrated unit.
 EAM is also referred as computerized maintenance management system.

It is the organized and systematic tracking of an organization’s physical
assets i.e. its plant, equipment and facilities.
EAM aims at
• Best utilization of its physical assets.
• It ensures generation of quality data and timely flow of required data
throughout the organization.
• It reduces paper work, improves the quality, quality and timeliness of the
information and.
• Provides information to be technicians at the point of performance and
gives workers access to job specific information at the work site.
• Computer-Aided Maintenance:
 It refers to systems that utilize software to organize planning, scheduling

and support of maintenance and repair.
 A common application of such systems is the maintenance of computers,
either hardware or software, themselves.
 It can also apply to the maintenance of other complex systems that
require periodic maintenance, such as reminding operators that
preventive maintenance is due or even predicting when such
maintenance should be performed on recorded past experience.
• Lean Maintenance:
 It is the application of lean principle in maintenance environments. Lean

system recognizes seven forms of waste in maintenance. They are over
production, waiting, transportation, process waste, inventory, waste
motion and defects.
 In lean maintenance, these wastes are identified and efforts are made for
the continuous improvement in process by eliminating the wastes.
 Thus, lean maintenance leads to maximize yield, productivity and
profitability.
• Total Productive Maintenance (TPM):
Total productive maintenance (TPM) is the process of using machines,

equipment, employees and supporting processes to maintain and improve
the integrity of production and the quality of systems. Put simply, it's the
process of getting employees involved in maintaining their own equipment
while emphasizing proactive and preventive maintenance techniques. Total
productive maintenance strives for perfect production.
• PILLAR 1-5S (SEIRI, SEITON, SEISO, SEIKETSU, SHITSUKE)
• PILLAR 2-JISHU HOZEN (Autonomous Maintenance)
• PILLAR 3-KAIZEN
• PILLAR 4-PLANNED MAINTENANCE
• PILLAR 5-QUALITY MAINTENANCE
• PILLAR 6-TRAINING
• PILLAR 7-OFFICE TPM
• PILLAR 8-SAFETY, HEALTH & ENVIRONMENT

Types of Maintenance
Preventive Corrective
Maintenance Maintenance
Deferred
Time Based
Corrective
Maintenance
Maintenance
(TBM)
(DCM)
Failure Finding
Emergency
Maintenance
Maintenance (EM)
(FFM)
Risk Based
Maintenance
(RBM)
Condition Based
Maintenance
(CBM)
Predictive
Maintenance
Review Questions:
Qno.1: Which type of maintenance is most expensive?
Qno.2: What is Breakdown Maintenance?
Qno.3: What is the difference between preventive maintenance and predictive
maintenance?
Qno.4: Are planned maintenance and preventive maintenance the same?
Qno.5: What about autonomous maintenance?
Qno.6: Which type of maintenance is most expensive?
Qno.7: Why is preventive maintenance better than breakdown maintenance?
Qno.8: Which is better preventive maintenance or predictive maintenance?
Maintenance KPIs:
For Repairable items
•MTBF (Mean Time Between Failures)
•MTTR (Mean Time To Repair)
•Availability
For Non-Repairable items

• MTTF (Mean Time To Failure)
Mean Time To Repair (MTTR)
Failure/Break down Repair Failure/Break down
Mean Time Between Failure (MTBF)

How to Calculate ?
Examples:
CNC Milling machine has production time of 640 hrs in
a month. And it suffered 40 break downs with down
time of 90 hrs. Calculate MTBF, MTTR and Availability.
MTTF applies to assets that are non-repairable—when
they fail, they are replaced.
Some examples of this type of equipment include:
• Transistors
• Fan belts in motors and engines
• Idler balls/rollers on conveyor belts
• Wheels on a forklift
• Lightbulbs
Calculate the MTTF of the conveyor belt rollers at your
facility. There are 125 identical rollers, which operated
a total of 60,000 hours in the last year.
Solution:
MTTF = Total hours of operation ÷ Total assets in use
MTTF = 60,000 hours ÷ 125 assets
MTTF = 480 hours
the average lifespan of a roller at your facility is 480

hours.

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Maintenance

• Maintenance Management is concerned with the direction and

1. To increase functional reliability of production facilities.

1. Breakdown (Reactive) Maintenance.

Reliability is defined as the probability that a product, system, or service will

3. Identify and document the work.

4. Development of repair plan.

5. Preparation tools and facilities list.

6. Estimation of time required to do the job.

• Requirement for Schedulers:

2. Man hour Backlog.

4. Availability of proper tools.

5. Availability of external manpower.

6. Availability of special equipment.

1. Weekly general schedule.

1. Reliability Centered Maintenance (RCM).

2. Six Sigma Maintenance.

3. Enterprise Asset Management (EAM).

4. Computer Aided Maintenance.

 Reliability-Centered Maintenance, often known as RCM is a process to

 Six Sigma is a set of techniques and tools for process improvement. It

 Enterprise Asset Management (EAM) is an information management

 EAM is also referred as computerized maintenance management system.

 It refers to systems that utilize software to organize planning, scheduling

 It is the application of lean principle in maintenance environments. Lean

Total productive maintenance (TPM) is the process of using machines,

• PILLAR 2-JISHU HOZEN (Autonomous Maintenance)

• PILLAR 4-PLANNED MAINTENANCE

• PILLAR 5-QUALITY MAINTENANCE

• PILLAR 7-OFFICE TPM

• PILLAR 8-SAFETY, HEALTH & ENVIRONMENT

For Non-Repairable items

Failure/Break down Repair Failure/Break down

Mean Time Between Failure (MTBF)

Some examples of this type of equipment include:

MTTF = Total hours of operation ÷ Total assets in use

MTTF = 60,000 hours ÷ 125 assets

MTTF = 480 hours

the average lifespan of a roller at your facility is 480

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