maintenance management

Submitted to-Ms Pritika Pathak

Presented ByMohan Gupta (ME-B) 090106130 TERM-VI

Acknowledgement
I take this opportunity with much pleasure to thank all the people who have helped me through the course of my journey towards producing this presentation. I sincerely thank my subject Incharge , Astt. Prof. Ms.Pritika Pathak for his guidance, help and motivation and also having faith in me for this topic. Apart from the subject of my study, I learnt a lot from her, which I am sure will be useful in different stages of my life. I would like to express my gratitude to Sharda University Which gave such a great platform where I can learn as much I can. I Mohan Gupta hereby declare that I tried a lot to capture all the things related to the topic Maintenance Management in a nutshell. The contents of these slides based on information generally available to the public from sources believed to be reliable.

What is Maintenance
The term maintenance means to keep the equipment in operational condition or repair it to its operational mode. Maintenance can be defined as a combination of actions carried out to replace,repair,service (or modify) the components or some identifiable grouping of components in a manufacturing pant. So that it will continue to operate at a specified availability for a specified time.

What is maintenance management

It is concerned with the organization and direction of resources in order to control the availability and performance of industrial plant to some specified level.

Objectives of maintenance management

Main objective of the maintenance is to have increased availability of production systems, with increased safety and optimized cost. The objectives of maintenance are to ensure the desired plant availability at an optimum cost within the safety prescription. it may be mentioned that the objective of maintenance is to minimize the total cost of unavailability and resources.

Objectives of maintenance management

Minimum breakdown time. Utilization of optimum capacity. To keep the life of equipment. To ensure highest availability. To modify the machine tools and other production facilities. Economy Improve productivity Ensure safety

Functions of maintenance
1. To develop maintenance policies, procedures and standards for the organization. 2. To ensure scheduled inspection and lubrication of plant, machinery and equipment. 3. To carry out periodic inspections of equipment and facilities to know which may lead their breakdown and storage. 4. Inspection and lubrication of existing equipment. 5. monitoring of faults and failures using appropriate techniques

Functions of maintenance
i.

ii.
iii.

iv.
v.

To keep record of all maintenance work. To insure scheduled inspection and lubrication of plant ,machinery and equipment. Maintenance of installed equipment and facilities. Installations of new equipment and facilities.

Modifications of already installed equipment and facilities. vi. Management of inventory. vii. Supervision of manpower. viii. Good housekeeping ix. To handle deposition of scrap or surplus material.

Types of maintenance
BREAKDOWN MAINTENANCE. ROUTINE MAINTENANCE. PLANNED MAINTENANCE.

PREVENTIVE MAINTENANCE.
CORRECTIVE MAINTENANCE.

BREAKDOWN MAINTENANCE
Characteristics of Break-down Maintenance System:
* No services except occasional lubrication unless failure occurs * No maintenance men on regular basis * Maintenance done by sub-contractors * No organized efforts to find out reasons * No stock of spares * No budget * No records * Initially it looks economical

Results of Breakdown Maintenance System:

* Increased Down Time * Increased costs & Pressures

ROUTINE MAINTENANCE
A procedure followed regularly i.e.,., A cyclic operation recurring periodically. Advantages 1. Simple to establish & follow 2. Little or no clerical work 3. High degree of prevention by intercepting developing faults. A more advanced stage of routine maintenance calls for 'service instructions on a pre-printed schedule and checklists'. Examples: * Check all compressors first on Mondays. * Lubricate completely two machines daily.

Disadvantages * Routine maintenance may not provide the service specified by the manufacturer * We may ignore information regarding preceding breakdowns * Service required for a machine at different frequencies may be ignored * All similar machines may be serviced at same frequency irrespective of working hours.

PLANNED MAINTENANCE
Characteristics of Planned Maintenance * Instructions are more detailed than in routine maintenance * Calls for differently timed service for the same unit * Schedule is drawn with dates * Need for establishing the work-load for the crew * Entails considerable planning effort, faithful implementation and recording

Advantages of Planned Maintenance

* Will take into consideration the changes in conditions of use and increased wear of parts * Inspections, replacement of parts and adjustments are included in the overall plan * Detailed instructions reduce the chance of missing any activity. Unforeseen work is greatly reduced * Provides as much attention as the equipment requires to the best judgment and ability of the planner

PREVENTIVE MAINTENANCE
System which strives to reduce the likelihood of failures. To achieve prevention of breakdowns Planned service is carried out with the explicit additional objective of detecting wear points and ensuring perfect functioning by replacing parts which could still be used were it not for the assurance that is required.
Occasional use of statistical analysis/methods for determining life expectancies of parts. The system employs Measuring & Inspection Devices. This phase is Predictive maintenance

Preventive Maintenance System

Preventive Maintenance System is more expensive due to more of planning and replacement of parts before failing. PM increases reliability PM reduces total work-load PM reduces total down time PM reduces unplanned work PM reduces total maintenance cost Routine maintenance & Planned maintenance also include Preventive maintenance action. Preventive maintenance could be grouped as under: -Fixed-time Maintenance - Condition-based Maintenance - Opportunity Maintenance

Corrective Maintenance
Services carried out to restore an item to an acceptable working condition.

Services arising out of

- Break-downs
- Malfunctioning & - Deteriorating conditions

PLANNING & SCHEDULING OF MAINTENANCE WORK

Basic requirements of organizing planning and scheduling of maintenance work are: To the extent possible a separate and a capable person should handle the planning and scheduling work and he would report to the In-charge of the Maintenance Department. He should be responsible for co-ordinating the

a) Schedule of maintenance personnel

b) Spare parts stock control, and c) Shutdown or breakdown time control This person will assist Maintenance In-charge in evolving the maintenance methods, develop and improve them, development of new maintenance tools and materials

SOURCES OF SCHEDULING DATA

1. Repair note is the primary source of information for scheduling purpose.
2. Maintenance Methods and time estimates, evolved earlier for various maintenance work, will give information regarding the various trades and the workload involved.

3. Load schedule and the progress report of the various maintenance crews will give information with respect to their availability.

4. Special Material for maintenance and Spare Parts records in the stores will be the source of information as to their availability.
5. Plant

Production schedule is the source of information as to the time when the equipment could be available for maintenance work and necessary servicing.

TYPES OF SCHEDULES

The size of the maintenance organization and the complexity of the plant's maintenance functions. Which will determine the types and frequency of schedules. In general, however, there are three principal classes of schedules which should be used regardless of the plant size. They are:

1. The preventive maintenance master overhaul and inspection schedule. 2. The daily man assignment schedule.
3. The area maintenance schedule.

MAINTENANCE CONTROL
Maintenance Control can be of three types as follows:1. Work Control 2. Equipment Control 3. Cost Control Work Control is done through periodic reporting of the progress of various maintenance activities. Equipment Control is the process of carrying out

MAINTENANCE CONTROL
Failure Analysis and Downtime Analysis and of taking corrective measures such as Design-out Maintenance and Design-for Maintenance. Cost control is exercised by the identification of high-cost areas through periodic reporting of PM Costs & CM Costs department/section/equipment-wise and initiating necessary action to reduce the same.