Maintenance
Management
ASSIGNMENT -2
[Topics 1-6]
Submitted To :
Dr. Rajani Jain
Submitted By:
1.
2.
3.
4.
K.D. Prakaash(08)
Rahul Raman(15)
Riya Gupta (17)
Rohit Kr. Mishra(18)
1. What is Maintenance? What are challenges to
maintenance function of a modern industry?
Maintenance:
The dictionary defines maintenance as follows: the work of
keeping something in proper condition; upkeep. This would imply
that maintenance should be actions taken to prevent a device or
component from failing or to repair normal equipment
degradation experienced with the operation of the device to keep
it in proper working order.
Maintenance in other words means
Maximize production output
Optimize the product quality
Maintenance is a function to keep the equipment/machine
condition by replacing or repairing some of the components of the
machine. The maintenance concept is an outline plan of how the
3 maintenance function will be performed. Based on the feedback
obtained from the users and the history of the equipment,
detailed procedures are drawn to concretize the maintenance
concept.
Challenges in Maintenance:
The maintenance function of a modern industry faces a number of
challenges attributable to:
Rapid growth of technology resulting in current technology
becoming obsolete. Such a challenge is a frequent one in
Information and Communications Technology (ICT) industry where
computers and computers based system is the main component.
Advent of new advanced diagnostic tools, rapid repair systems,
etc.
Advance store management techniques to incorporate modular
technologies.
Requirements of keeping both outdated and modern machines
in service.
For example, many industrial organizations have a combination of
the old machines working on obsolete technology and new
systems utilizing the latest technology and equipment. The
effective management of maintenance aspects under such
challenging circumstances is often a difficult job. Besides the
rectification of the faults in the equipment, the activities of the
maintenance department include:
1. Up gradation of the existing plants and equipment and
training maintenance personnel to attend the required
technical skills.
2. Effective maintenance of the old equipment for higher
availability
3. Cost optimization of all maintenance functions
4. Improvement of maintenance activities in the areas of
tribology and terro-technology.
5. Reconditioning of used /unserviceable spare parts.
6. Development of indigenous sources for parts for import
substitution.
7. Setting up of an effective maintenance information
management systems (MIMS).
8. Effective utilization of the maintenance workforce
9. Setting up of in house R&D activities for effecting
improvements in maintenance practices.
2. What is systems approach to Maintenance?
A systems approach to maintenance involves setting up of
objectives, planning, executing and controlling the maintenance
functions, not as isolated function but as the part of corporate
policies and strategies aimed at achieving the well-defined goals
of an organization. Internally the maintenance function
coordinates its activities with other functions like production and
sales and externally, it ensures the availability of quality spares,
trained manpower, and replacement of worn equipment and so
on. This approach takes into account all the relevant interacting
functions, factors and facts both internal and external to the
system.
Once the objectives are set, the systems approach includes the
following:
Identification of the need of maintenance
Analyzing the requirement for the above needs
Determining the functional procedures
Outlining a reporting and controlling procedure
Developing support facilities and infrastructure
Determining the cost accounting procedures
Adopting a policy for training and quality assurance
Thus, the systems approach is applied to ensure
maintenance performance for a particular situation
better
3. What are the objectives of Maintenance?
The objectives of maintenance should be formulated within the
framework of the overall organizational setup so that finally the
goals of the organization are accomplished. The most important
objective of maintenance is the maximizing the availability of
equipment or facilities so as to extend help for achieving the
ultimate goals of the organization. Second important objective is
the establishment of safe working conditions both for operating
and maintenance personnel.
Other Objectives include:
Elimination of future defects
Prevent breakdown during operation
Ensure safety during operation
Maximize operational efficiency
Reduce idle hours due to component malfunctioning
Reduce maintenance cost
Enhance performance level
Forestall rapid wear of components
4. What are responsibilities of Maintenance
Department?
Management Responsibility:
The maintenance department should be able to make goals,
plan, organize and control the activities.
All goals should be specific, quantifiable, and well-defined
with an estimated time of achievement of the goal.
Each goal should be communicated freely and clearly to all
those who are involved in the process.
Goals should be reviewed regularly by maintenance
manager, maintenance supervisor.
Organization:
Plant maintenance, engineers, productions and operations
should share the responsibility in a coordinated effort of
optimizing the performance.
Responsible for safe, efficient, and technically sound
execution of maintenance work.
Have accountability for maintenance cost.
Administration:
Program coordination for the Department and liaison with all
other Departments for the procurement and maintenance of
all real property, production equipment, utility services, and
communication services.
Preparation
of
Maintenance
Department
budgets.
Coordination with other Departments in the preparation of
their maintenance budgets.
Preparation of project cost estimates; proposal, justification,
and management of capital projects and expenditures.
Maintenance of records of planned and current construction
and maintenance contracts.
Designing, specifying, installing, and maintaining all fire
protection and security systems.
Assuring compliance with all applicable life safety and
building code and regulations.
Provision of first-response capability for all life-threatening
and property threatening emergencies.
Maintaining liaison with local community emergencyresponse and law-enforcement organizations for assistance
as required.
Conducting necessary security checks, inspections, surveys,
and investigations to assure that the required standards of
physical security are maintained.
Utility Operations and Energy Management:
Procurement of fuels and energy
Liaison with public utilities
Specifying, operating and maintaining backup utility
systems.
Operations and maintenance of all utility systems.
Compliance with all applicable federal, state and local codes,
statues and regulations.
Environmental Concern:
Maintain set of state and local quality standards and
company compliance requirements.
Identify and record equipment monitored and breakdowns.
Monitoring devices, reporting and alarms.
Equipment maintenance, repairs, replacement and reporting.
Maintain record of tests and inspection of drinking water of
the industry to quality and standards.
5. What are different types of Maintenance
Systems? Discuss all of them in 5-10 sentences
each.
Predictive maintenance
It involves a series of steps prior to actually performing
maintenance. It begins with sampling physical data over time,
such as vibration or particulate matter in oil. Analysis is then
performed on the collected data to create an appropriate
maintenance schedule, and maintenance is performed according
to the schedule. This type of maintenance analysis works well for
mechanical systems because the failure modes are well
understood. Additionally there is historical data useful for
creating and validating performance and maintenance models
for mechanical systems.
Preventative maintenance
It refers to maintenance performed when a system is functioning
properly to prevent a later failure. Generally, it is performed on a
regular basis and the maintenance will be performed regardless
of whether functionality or performance is degraded. The
frequency of the maintenance is generally constant, and is
usually based on the expected life of the components being
maintained, but there is not necessarily any monitoring occurring
at the same time (as there would be in predictive maintenance).
One common example is lubrication of mechanical systems after
a certain number of operating hours. Another is replacement of
lightning arresters in jet engines after a certain number of
lightning strikes.
Corrective maintenance
It refers to maintenance done to correct a problem when
something has failed, or is failing. The need for corrective
maintenance can be beneficial or detrimental depending on the
product and the profit model used during the design phase of the
product. On the most obvious level, corrective maintenance is
detrimental to operation because it means that something failed,
and the system is (probably) not available during the time
needed to perform the maintenance. On the other hand, it may
be that the economics and planned functionality of a system are
such that using a cheaper, replaceable device for which failure is
anticipated, makes sense.
Run to failure Maintenance
The required repair, replacement, or restore action performed on
a machine or a facility after the occurrence of a failure in order to
bring this machine or facility to at least its minimum acceptable
condition. It is the oldest type of maintenance. It is subdivided
into two types:
Emergency maintenance
Breakdown maintenance
Use: The failure of a component in a system is unpredictable. The
cost of performing run to failure maintenance activities is lower
than performing other activities of other types of maintenance.
The equipment failure priority is too low in order to include the
activities of preventing it within the planned maintenance budget.
Improvement Maintenance
It aims at reducing or eliminating entirely the need for
maintenance. This type of maintenance is subdivided into three
types as follows:
1. Design-out maintenance which is a set of activities that are
used to eliminate the cause of maintenance, simplify
maintenance tasks, or raise machine performance from the
maintenance point of view by redesigning those machines and
facilities which are vulnerable to frequent occurrence of failure
and their long term repair or replacement cost is very
expensive.
2. Engineering services which includes construction and
construction modification, removal and installation, and
rearrangement of facilities.
3. Shutdown improvement maintenance, which is a set of
improvement maintenance activities that are performed while
the production line is in a complete stoppage situation.
6. What is Maintability?
Characteristic of design
and installation which
determines
the probability that a failed equipment, machine, or system can
be restored to its normal operable state within a given
timeframe, using the
prescribed practices and procedures
is
called
maintainability.
Its
two
main components are serviceability (ease
of
conducting scheduled inspections and servicing) and reparability
(ease of restoring service after a failure).
Maintainability is the ease
maintained in order to:
with
isolate defects or their cause,
correct defects or their cause,
which
product
can
be
repair or replace faulty or worn-out components without
having to replace still working parts,
prevent unexpected breakdowns,
maximize a product's useful life,
maximize efficiency, reliability, and safety,
meet new requirements,
make future maintenance easier, or
Cope up with a changed environment.
7. What are principles of Maintenance?
These are the principles:
Plant management in maintenance work
Maintenance objective Vs. Plant production
Establishment of work order and recording system
Information based decision making
Planning of maintenance functions
Manpower for maintenance
Workforce control
Quality and availability of spare parts
8. Discuss elements of Planned Preventive
Maintenance ?
Planned preventative maintenance is an ever-increasing aspect of
building asset management. A PPM provides for the renewal of
these elements before they fail and cause expensive knock-on
damage to other building elements. Having a detailed and wellcosted PPM in place for your property provides a level of comfort,
possible significant future savings and allows you to spread your
maintenance costs over a planned period of time.
There are the
maintenance:
basic
elements
of
planned
Deterioration Probability
Failure probability
Cost of periodic maintenance
Expenditure towards maintenance personnel
Cost of system downtime
Supportive services
Facility register
Equipment record sheet/card
Maintenance scheduling
preventive
Work specifications
Maintenance records and documentations
Spare parts inventory
9. Discuss Maintenance by Objectives?
The objective of maintenance work should be to strike a balance
between the availability and the overall running costs.it is a
management area that can be applied in the area of
maintenance. The maintenance personnel can select the areas of
improvement. The incentives for the improvement are decided by
the organization and also the areas where improvement can be
possible are well-defined. Then the standards for the
performances are set and means of measuring results are also
agreed upon. The objectives can be cost-dependent or
performance-related, depending upon the type of equipment
being used.
The objectives of finance personnel are normally conflicting to
those of maintenance personnel. There must be commitment by
the maintenance personnel, particularly the maintenance chief, to
meet the department objectives in consonance with the financial
objectives.
Maintenance by objectives is the real approach to meeting the set
objectives. It can be useful in evaluating the performance of the
foreman, motivating the personnel to make commitments to
achieve satisfactory results with their own objectives.to obtain
motivational value from MBO programme, the maintenance chief
must be able to spell out his department objectives and then
clearly communicate them to his foremen and other related
persons.
MBO can also be an effective tool for sharpening the operating
skills of the maintenance personnel. This is only possible where
there is close cooperation between the maintenance engineer and
his staff. The improvement in the performance of the personnel
can be assessed with the help of MBOs taking care of the
following:
The attitude of the staff to improve themselves and the
maintenance engineer help them to achieve their goals.
What level of guidance is required? Is the staff being asked
to do more than what they really can do?
________________________________________________________________
10. How is work Planning and scheduling carried
out in Planned Preventive Maintenance?
Effective planning and scheduling contribute significantly to the
following:
Reduced maintenance cost.
Improved utilization of the maintenance workforce by
reducing delays and interruptions.
Improved quality of maintenance work by adopting the best
methods and procedures and assigning the most qualified
workers for the job.
Minimizing the idle time of maintenance workers.
Maximizing the efficient use of work time, material, and
equipment.
Maintaining the operating equipment at a responsive level to
the need of production in terms of delivery schedule and
quality.
PLANNING:
It comprises all the functions related to the preparation of:
The work order
Bill of material
Purchase requisition
Necessary drawings
Labor planning sheet including standard times
All data needed prior to scheduling and releasing the
work order.
The procedure of planning:
1. Determine the job content.
2. Develop work plan. This entails the sequence of the activities
in the job and establishing the best methods and procedures
to accomplish the job.
3. Establish crew size for the job.
4. Plan and order parts and material.
5. Check if special tools and equipment are needed and obtain
them.
6. Assign workers with appropriate skills.
7. Review safety procedures.
8. Set priorities for all maintenance work.
9. Assign cost accounts.
10.
Complete the work order.
11.
Review the backlog and develop plans for controlling it.
12.
Predict the maintenance
forecasting technique.
load
using
effective
SCHEDULING:
Scheduling deals with the specific time and phasing of planned
jobs together with the orders to perform the work, monitoring the
work, controlling it, and reporting on job progress. Successful
planning needs a feedback from scheduling.
Requirements for effective scheduling:
Written work orders that are derived from a well-conceived
planning process. (Work to be done, methods to be followed,
crafts needed, spare parts needed, and priority).
Time standards.
Information about craft availability for each shift.
Stocks of spare parts and information on restocking.
The procedure of scheduling:
1. Sort backlog work orders by crafts.
2. Arrange orders by priority.
3. Compile a list of completed and carry over jobs.
4. Consider job duration, location, travel distance, and the
possibility of combining jobs in the same area.
5. Schedule multi-craft jobs to start at the beginning of every
shift.
6. Issue a daily schedule (not for shutdown maintenance).
7. Authorize a
(dispatching).
supervisor
to
make
work
assignments
11. Discuss the Indices used for Maintenance
Evaluation in Garment Industry?
12.
Discuss the four
Function Evaluation?
types
of
Maintenance
Evaluation through reports:
The evaluation is done on the basis of reports which are prepared
at fixed time intervals (monthly or yearly) giving details of the
equipment serviced/maintained during period. The real evaluation
of the process depends upon the accuracy of the reports. The
reports should give the complete picture of the maintenance
function so that the corrective measures can be taken.
Subjective evaluation:
It is a qualitative type of evaluation. Evaluation is not expressed
in numerical values but expressed in qualitative estimates like
good , fair , adequate etc. Evaluation will depend upon the
available expertise on the subject, qualifications of the working
people and their training.
Objective evaluation:
A number of indices are frequently used for objective evaluation.
These include:
The ratios
given above helps helpful in assessing the maintenance costs.
The ratios defined above can be computed on monthly or yearly
basis. These ratios are indicative of the performance of
maintenance personnel.
Work auditing:
In this method total time for which the equipment is not available
for production work and total time taken by maintenance staff to
attend the fault is analyzed . The step by step progress of
randomly selected job is recorded to highlight the delays caused.
The delay may be because of poor planning of repair work or nonavailability of spare parts. It enables the maintenance foreman to
understand the weak points. The areas where improvements are
possible can be identified and corrective actions initiated
accordingly.
13.Discuss the levels of condition monitoring ?
Level 1 Visual Inspections
The level 1 inspection form a part of the normal preventive
maintenance and are generally included in the daily and weekly
maintenance activities. The persons involved are expected to
sense the condition of equipment by seeing, touching and
smelling.
Level 2- Sensor Assisted Inspections
At this level the assessment is done by the available portable
instruments to make various measurements. The condition of the
lubricant or the presence of the ear debris in the gear box oil or
engine oil can be used as the indicators of the condition of the
system.
Level 3- Indicator Analysis
In this analysis the indicator analyses used in level 2 are used. For
such analysis sophisticated test laboratories are must.
Level 4- Integral Monitoring Applications
This condition monitoring can be carried out with the help of
minicomputers or microprocessors. Here, process transducers,
accelerometers, counters and other sensors are employed at
different points of equipment for acquisition of data to indicate
the failure of the system. However level 4 require more cost and
high skills and thus, is suitable for large scale industries only.
14. Discuss the aspects to be considered while
planning maintenance work?
Job Distribution
Organizational Goals
Policies
Procedures
15. Discuss the various planning techniques used
in Maintenance Planning.
16. Discuss the methods used for estimation of
maintenance work.
During planning, it is important to estimate the quality and
quantity of the maintenance work. The following three methods
can be used for the estimation of the maintenance work:
1. Measurement by Estimates
This system is more useful where material cost is negligible
compared to the labor cost. It consists of comparing the actual
cost of labor with the estimated cost. Benefits of this system are:
The estimate of the total time is prepared before the start of
the job.
The estimate provides the basis of scheduling maintenance
work.
The estimate also provides the comparison with the actual
man hours changed during a particular operation.
2. Measurement by Historical Data
It consists of statistical analysis and treatment of past time data
of completed jobs to arrive at an average, which can be
considered a suitable standard. This method compares the actual
man hours required for the job with the standard index based on
average historical time for the same type of job. This method also
provides a basis for the estimation of a new type of work, where
details are not available. Advantages include:
Low cost of administration, because the required data can be
collected easily.
Adaptability to routine and repetitive type of jobs.
Easy installation for estimation of maintenance work.
Provision of immediate but limited improvement in labor
effectiveness.
3. Measurement by Conventional standard Time Data
Under this method the work is measured under the standard time
data by breaking down the job in components and applying the
standard time to each component. The sum of these standard
times and the variance allowances for job conditions represents
the time that should be allowed for the job. The work
measurement based on this method can be accurate only if the
application of the standard time on the components is done
correctly. The advantage of this method is sufficient time is
allowed for each job and thus the clusteration of various jobs is
avoided.
17. Describe the activities of maintenance function
falling in short range and long range planning.
