MAINTENANCE

MANAGEMENT
JACQUES S. OSMEÑA
Bachelor of Science in Industrial Engineering
COTE – Industrial Engineering Department
Introduction and Meaning
⦿ Past and current maintenance practices in both the private and Government
sectors would imply that maintenance is the actions associated with equipment
repair after it is broken.

⦿ It 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.

⦿ Nothing lasts forever and all equipment has associated with it some predefined
life expectancy or operational life.
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Objectives of Maintenance
It is an absolute necessity to maintain the
equipments in good operating conditions
with economical cost.

An integrated approach to minimize the

cost of maintenance.

It is needed for decision making whether

to replace the equipment or to retain the
old equipment by taking the cost of
maintenance and operation into account. 3
 Types of Maintenance

Breakdown (Reactive) Maintenance

It is basically the „run it till it breaks‟ maintenance mode. No actions
or effort are taken to maintain the equipment as the designer
orginally intended to ensure design life is reached.

Advantages to breakdown maintenance can be viewed as a double-

edged sword. If we are dealing with new equipment, we can expect
minimal incidents of failure. If our maintenance program is purely
reactive, we will not expend manpower or incur capital cost until
something breaks. Since we do not see any associated maintenance
cost, we could view this period as saving money.
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 Advantages Disadvantages

1. Involves low cost investment

1. Increased cost due to unplanned
for maintenance.
downtime of equipment.
2. Less staff is required. 2. Increased labor cost, especially if
overtime is needed.
3. Cost involved with repair or
replacement of equipment.
4. Possible secondary equipment or
process damage from equipment
failure.
5. Inefficient use of staff resources.
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 Types of Maintenance

Preventive Maintenance
Preventive maintenance can be defined as, “Actions performed on a
time or machine-run-based schedule that detect, preclude, or
mitigate degradation of a component or system with the aim of
sustaining or extending its useful life through controlling
degradation to an acceptable level.”

Preventive maintenance is a means to increase the reliability of their

equipment. By simply expending the necessary resources to conduct
maintenance activities intended by the equipment designer,
equipment life is extended and its reliability is increased.
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 Advantages Disadvantages
1. Cost effective in many capital intensive
processes. 1. Catastrophic failures still likely
to occur.
2. Flexibility allows for the adjustment of
maintenance periodicity.
2. Labour intensive.
3. Increased component life cycle.
3. Includes performance of
4. Energy savings. unneeded maintenance.

5. Reduced equipment or process failure.

4. Potential for incidental damage
6. Estimated 12% to 18% cost savings to components in conducting
over reactive maintenance program. unneeded maintenance.
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 Types of Maintenance

Predictive Maintenance
Predictive maintenance can be defined as
“Measurements that detect the onset of a degradation
mechanism, thereby allowing causal stressors to be
eliminated or controlled prior to any significant
deterioration in the component physical state. Results
indicate current and future functional capability”.
Basically, predictive maintenance differs from
preventive maintenance by basing maintenance need on
the actual condition of the machine rather than on some
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preset schedule. Preventive maintenance is time-based.
 Advantages Disadvantages
1. Increased component operational
1. 1. Increased investment in
life/availability.
diagnostic equipment.
2. Allows for pre-emptive corrective
actions. 2. Increased investment in staff
training.
3. Decrease in downtime and costs
with estimated 8-12%. 3. Savings potential not readily seen
by management.
4. Better product quality

5. Improve worker moral and

environmental safety.
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 Maintenance Planning

Planning of maintenance jobs basically deals with answering two questions, „what‟ and

„How‟ of the job; „what activities are to be done?‟ and „how those jobs and activities

are to be done?‟ While answering these two questions, other supplementary questions

are to be answered, e.g., „where the jobs is to be done?‟ and „why the job is to be

done?‟ etc., but all these will be helping in developing „what‟ and „how‟ of the job.
Steps of Job Planning
1. Knowledge base: It includes knowledge about equipment, job, available techniques, materials
and facilities.

2. Job investigation at site: It gives a clear perception of the total jobs.

3. Identify and document the work: Knowing the earlier two steps and knowing the needs of
preventive, predictive and other maintenance jobs.

4. Development of repair plan: Preparation of step by step procedures which would accomplish
the work with the most economical use of time, manpower and material.

5. Preparation tools and facilities list indicating the needs of special tools, tackles and facilities
needed.

6. Estimation of time required to do the job with work measurement technique and critical path
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analysis.
 Maintenance Scheduling

Scheduling is the function of coordinating all of the logistical issue around the issues

regarding the execution phase of the work. Scheduled of maintenance jobs basically

deals with answering two questions—„Who‟ and „When‟ of job, i.e., “who would do

the job” and “when the job would be started and done”. Effective scheduling

essentially needs realistic thinking, based on substantial data and records.

Requirements for Schedulers
A scheduler should also have knowledge about job, techniques, facilities, analytical ability and
judgmental courage. The scheduler must obtain knowledge/information about following ability and
judgmental courage. The scheduler must obtain information about following facts, before starting
his job:

1. Manpower availability by trade, location, shift, crew arrangement and permissible overtime limit
etc. 2. Man hour back log on current or unfinished jobs. 3. Availability of the equipment or area
where the work has to be performed. 4. Availability of proper tools, tackles, spares, consumables,
structural and other required materials. 5. Availability of external manpower and their capabilities;
these may be from other shops/ departments of the plant or from contractors (local, nearby, ancillary
). 6. Availability of special equipment, jigs/fixtures, special lifting and handling facilities and cranes
etc. This should also include labor and time saving devices like pneumatic hammers and excavators
etc. 13
 Maintenance Schedule Techniques

Different types of schedules are made suiting the respective job plans and different

techniques are used for making and following those schedules. The first step of all

scheduling is to break the job into small measurable elements, called activities and to

arrange them in logical sequences considering the preceding, concurrent and

succeeding activities so that a succeeding activity should follow preceding activities

and concurrent activities can start together.

 Different Types of Schedule:
Maintenance Schedule Techniques

Weekly General Daily Schedule Gantt Charts

Schedule
developed to provide a are used to represent the
made to provide weeks day‟s work for each timings of tasks required
worth of work for each maintenance employee to complete a project.
employee in an area. of the area.

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 Different Types of Schedule:
Maintenance Schedule Techniques

Bar Charts PERT/CPM

used for technical used to find the time

analysis which required for completion
represents the relative of the job and helps in
magnitude of the values. the allocation of
resources.

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Modern Scientific Maintenance Methods
Reliability Centered Maintenance
Defined as “a process used to determine the maintenance requirements
of any physical asset in its operating context”. RCM methodology deals
with some key issues not dealt with by other maintenance programs. It
recognizes that all equipment in a facility is not of equal importance to
either the process or facility safety.

It also approaches the structuring of a maintenance program recognizing

that a facility does not have unlimited financial and personnel resources and
that the use of both need to be prioritized and optimized.

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Modern Scientific Maintenance Methods
Six Sigma Maintenance
It is the application of six sigma principles in maintenance. Six sigma is a
maintenance process that focuses on reducing the variation in business
production processes. By reducing variation, a business can achieve tighter
control over its operational systems, increasing their cost effectiveness and
encouraging productivity breakthrough.

Six sigma relies heavily on statistical techniques to reduce failures and it incorporates
the basic principles and techniques used in Business, Statistics, and Engineering. Six
sigma methodologies can also be used to create a brand new business process from
ground up using design for six sigma principles.

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Modern Scientific Maintenance Methods
Enterprise Asset Management (EAM)
Enterprise asset management is an information management system that
connects 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.

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Modern Scientific Maintenance Methods
Lean Maintenance
Lean maintenance 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.

Lean maintenance is basically equipment reliability focused and reduces

need for maintenance troubleshooting and repairs.

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Modern Scientific Maintenance Methods
Computer Aided Maintenance
For effective discharge of the maintenance function, a well designed
information system is an essential tool. Such systems serve as effective
decision support tools in the maintenance planning and execution. For
optimal maintenance scheduling, large volume of data pertaining to men,
money and equipment is required to be handled. This is a difficult task to be
performed manually.

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 Total Productive Maintenance Plan
A maintenance program, which involves a newly defined concept for maintaining plants and

equipment. The goal of the TPM program is to markedly increase production while, at the same

time, increasing employee morale and job satisfaction. It can be considered as the medical

science of machines. TPM brings maintenance into focus as a necessary and vitally important part

of the business.

Downtime for maintenance is scheduled as a part of the manufacturing day and, in some cases, as

an integral part of the manufacturing process. The goal is to hold emergency and unscheduled

maintenance to a minimum.
Following Objectives
1. Avoid wastage in a quickly changing
economic environment.

2. Producing goods without reducing

product quality.

3. Reduce Cost

4. Produce a low batch quantity at the

earliest possible time.

5. Goods send to the customer must be

non-defective.
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Similarities and Difference between
TQM and TPM
The TPM program closely resembles the popular Total Quality Management
(TQM) program. Many of the tools such as, employee empowerment,
benchmarking, documentation, etc. used in TQM are used to implement and
optimize TPM.

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Similarities and Difference between
TQM and TPM
Following are the similarities between the two: 1. Total commitment to the
program by upper level management is required in both programs, 2.
Employees must be empowered to initiate corrective action, and 3. A long-
range outlook must be accepted as TPM may take a year or more to implement
and is an on-going process. Changes in employee mind-set toward their job
responsibilities must take place as well.

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Pillars of TPM

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Skill Development #7
Use the production or service facilities you used
in the past activity and get the information for
the following questions:
1. Types of Maintenance of Equipment used
2. Maintenance Schedule followed.
(Maintenance Schedule Techniques and
Modern Scientific Maintenance Method)
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Thanks!