Maintenance Management - Sheet For 433-35!37!39
Maintenance Management - Sheet For 433-35!37!39
Maintenance Management - Sheet For 433-35!37!39
Since the Industrial Revolution, maintenance of engineering equipment in the field has been a
challenge. Although impressive progress has been made in maintaining equipment in the field in
an effective manner, maintenance of equipment is still a challenge due to factors such as size,
cost, complexity, and competition. Each year billions of dollars are spent on equipment
maintenance around the world. Over the years, many new developments have taken place in this
area. maintenance activities are viewed as those that use resources in physically performing those
actions and tasks attendant on the equipment maintenance function for test, servicing, repair,
calibration, overhaul, modification, and so on.
Maintenance
All actions appropriate for restoring an item/part/equipment in, or restoring it to, a given
condition. Maintenance is a function that must be performed under normally adverse
circumstances and stress, and its main objective is to rapidly restore the equipment to its
operational readiness state using available resources.
Maintenance Management
The broad indices indicate the overall performance of the organization with respect to
maintenance and the specific indices indicate the performance in particular areas of the
maintenance function. The values of all these indices are plotted periodically to show trends.
BROAD INDICATORS
Index I
This is defined by:
Where
TMC = total maintenance cost,
TS = total sales,
I1 = index parameter.
Past experience indicates that average expenditure for maintenance for all industry was around
5% of sales.
Index II
This is expressed by,
I2 =
Where,
TIPE Total investment in plant and equipment.
This index relates the total maintenance cost to the total investment in plant and equipment. The
approximate average figures for I3 in the steel and chemical industries are 8.6% and 3.8%,
respectively.
SPECIFIC INDICATORS
Index III
This is a useful index to control preventive maintenance activity within a maintenance
organization and is defined by,
I3=
where
I3 = index parameter,
TTPM = total time spent in performing preventive maintenance,
TTEP = total time spent for the entire maintenance function.
As per the past experience, the value of I4 should be kept within 20 and 40% limits.
2. Set maintenance goals: These goals take into consideration existing deficiencies and
identify targets for improvement.
5. Establish short- and long-range plans: The short-range plan focuses on high-priority
goals, usually within a one-year period. The long-range plan is more strategic in nature
and identifies important goals to be reached within three to five years.
6. Document both long- and short-range plans and forward copies to all concerned
individuals.
7. Implement plan.
8. Report status: Preparing a brief report periodically, say semi-annually, and forward it to
all involved individuals. The report contains for each objective identified in the short-
range plan information on actual or potential slippage of the schedule and associated
causes.
9. Examine progress annually: Review progress at the end of each year with respect to
stated goals.
Types of Maintenance:
Preventive Maintenance
A formula to Use:
- To decide which preventive maintenance policy to implement
Where,
CPMS = total cost of preventive maintenance system
= a factor whose value is proposed to be taken as 70% or 0.7; more specifically, 70% of the
total cost of breakdowns
NB = Number of Breakdowns,
ACPBD = Average Cost per Breakdown.
Example:
For a machine, number of breakdown 5, for each breakdown the cost is 4500 taka. The current
policy will cost 18000 taka. Is the policy suitable for the machine?
Solution:
NB=5
ACPBD=4500
= 0.7
CPMS = 18000
So, here the (NB)(ACPBD) > CPMS relation holds. So this policy is suitable.
Advantages:
Increase in equipment availability
Performed as convenient
Increase in production revenue
Consistency in quality
Reduction in parts inventory
Improved safety
Disadvantages:
Exposing equipment to possible damage
Using a greater number of parts
Demands more frequent access to equipment/item
Corrective Maintenance
Corrective maintenance is a maintenance task performed to identify, isolate, and rectify a fault so
that the failed equipment, machine, or system can be restored to an operational condition. It is
opposite of preventive maintenance which is scheduled.
That corrective maintenance is composed of five major sequential steps, as shown in figure
below. These steps are: fault recognition, localization, diagnosis, repair, and checkout.
The major corrective maintenance downtime components are active repair time, administrative
and logistic time, and delay time.The active repair time is made up of the following
subcomponents:
Preparation time
Fault location time
Spare item obtainment time
Fault correction time
Adjustment and calibration time
Checkout time
Efficiency in fault recognition, location, and isolation: Past experience indicates that in
electronic equipment, fault isolation and location consume the most time within a
corrective maintenance activity. Factors such as well designed fault indicators, good
maintenance procedures, well-trained maintenance personnel, and an unambiguous fault
isolation capability are helpful in lowering corrective maintenance time.
Redundancy: This is concerned with designing in redundant parts that can be switched in
at the moment of need so the equipment/system continues to operate while the faulty part
is being repaired.
Effective accessibility: Often a significant amount of time is spent accessing the failed
part. Proper attention to accessibility during design can help reduce part accessibility time
and, in turn, the corrective maintenance time.
Human factor considerations: Attention paid to human factors during design in areas
such as readability of instructions, size, shape, and weight of components, selection and
placement of dials and indicators, size and placement of access, gates, and readability,
and information processing aids can help reduce corrective maintenance time
significantly.
Maintenance Policy
Set of administrative, technical and managerial actions to apply during the life cycle of a
machine.
Example of maintenance policy:
Independent Breakdown Replacement
Group Breakdown Replacement
Individual Preventive Replacement
Group Preventive Replacement