ASSIGNMENT ON PRODUCTION AND OPERATIONS RESEARCH

MINI-PROJECT ON THE TOPIC

‘MAINTENANCE MANAGEMENT’

BENGALURU CITY UNIVERSITY

ABDUL RAZIQUE VK

REG NO:P18AJ23M015004

I YEAR MBA
Under the guidance of

Dr.Venkaiah Babu

Department of MBA

Acharya Institute of Graduate Studies

(NAAC Re-accredited ‘A+’Grade and Affiliated to Bangaluru City University)

2023-2024
CONCEPT OF MAINTENANCE MANAGEMENT

Maintenance management refers to the systematic process of ensuring that resources such as
machinery, equipment, and infrastructure are in optimal working condition. It encompasses
planning, organizing, and supervising maintenance activities to reduce equipment downtime,
enhance safety, and boost operational efficiency. Maintenance management is particularly
significant in industries such as manufacturing, transportation, and healthcare, where the
reliability of equipment is directly linked to productivity.

The primary goals of maintenance management include:

 Extending Asset Lifespan: Regular maintenance helps assets last longer, reducing
the need for frequent replacements.
 Reducing Operational Costs: By addressing issues early, organizations can avoid
costly emergency repairs.
 Minimizing Disruptions: Proactive maintenance ensures smooth operations without
unexpected interruptions.
 Ensuring Compliance: Adherence to safety and regulatory standards prevents legal
complications and enhances workplace safety.

Effective maintenance management combines modern technologies, skilled personnel, and

strategic planning to achieve these objectives. This approach contributes to both immediate
operational success and long-term organizational growth.
FUNCTIONS OF MAINTENANCE MANAGEMENT

Maintenance management involves a variety of functions that ensure the smooth operation of
assets and infrastructure. These functions include:

A. PLANNING

 Maintenance Schedules: Developing detailed schedules to conduct inspections and

servicing at regular intervals.
 Resource Allocation: Ensuring the availability of manpower, tools, and spare parts
for efficient execution.
 Task Alignment: Synchronizing maintenance activities with production schedules to
minimize conflicts.

B. ORGANIZING

 Team Structuring: Establishing a well-defined hierarchy and roles within the

maintenance team.
 Coordination: Bridging communication gaps between departments to align
maintenance efforts with operational goals.
 Prioritization: Assigning urgency levels to tasks based on their impact on operations.

C. MONITORING AND CONTROL

 Performance Tracking: Measuring the effectiveness of maintenance activities using

KPIs like mean time to repair (MTTR) and mean time between failures (MTBF).
 Adjustments: Modifying strategies based on performance analysis to enhance
outcomes.
 Reporting: Documenting maintenance activities for transparency and future
reference.

D. DECISION-MAKING

 Repair vs. Replace: Evaluating whether repairing an asset or replacing it is more

cost-effective.
  Budget Allocation: Determining maintenance budgets based on organizational
priorities and resource availability.
 Technology Integration: Introducing advanced tools and techniques to improve
maintenance efficiency.

E. SAFETY AND COMPLIANCE

 Safety Standards: Ensuring that equipment operates within safety parameters to

prevent accidents.
 Inspections: Conducting periodic checks to identify and mitigate potential risks.
 Training: Educating staff about safety protocols and equipment handling to reduce
workplace hazards.
TYPES OF MAINTENANCE
A. PREVENTIVE MAINTENANCE

Preventive maintenance involves performing regular inspections and servicing to prevent

equipment failures before they occur. This proactive approach ensures equipment remains in
good working condition.

Advantages:

 Reduces unexpected downtime and production delays.

 Extends the useful life of machinery.
 Improves workplace safety by identifying risks early.

Disadvantages:

 Requires careful planning and scheduling.

 May lead to over-maintenance if performed unnecessarily.
 Higher upfront costs due to frequent servicing.

B. PREDICTIVE MAINTENANCE

Predictive maintenance relies on real-time data and advanced analytics to predict when
equipment is likely to fail. This allows maintenance teams to address issues before they
escalate.

Advantages:

 Minimizes downtime by targeting specific issues.

 Reduces overall maintenance costs.
 Enhances reliability and operational efficiency.

Disadvantages:

 High initial investment in monitoring tools and technology.

 Requires skilled personnel to interpret data.
  Limited applicability for certain types of equipment.

C. CORRECTIVE MAINTENANCE

Corrective maintenance involves repairing or replacing equipment after it has failed. This
reactive approach is often used for non-critical assets.

Advantages:

 Simple and cost-effective for minor issues.

 Requires no advanced planning or monitoring.

Disadvantages:

 Leads to unplanned downtime.

 Can pose safety risks if critical failures occur.
 Higher long-term costs due to repeated breakdowns.

D. CONDITION-BASED MAINTENANCE

Condition-based maintenance monitors the actual condition of equipment and performs

maintenance only when necessary. This approach uses data from sensors and inspections to
determine the right time for servicing.

Advantages:

 Optimizes maintenance schedules, reducing waste.

 Increases asset performance by addressing specific needs.
 Avoids unnecessary maintenance, saving time and resources.

Disadvantages:

 High implementation costs due to advanced monitoring equipment.

 Relies on accurate and consistent data.
 Requires skilled personnel for analysis and decision-making.
E. EMERGENCY MAINTENANCE

Emergency maintenance addresses unexpected equipment failures that require immediate

attention. It is often critical for maintaining operations during emergencies.

Advantages:

 Ensures quick resolution of critical failures.

 Maintains continuity in essential operations.

Disadvantages:

 Disrupts planned activities, leading to inefficiencies.

 Expensive due to urgency and lack of preparation.

TOTAL PRODUCTIVE MAINTENANCE (TPM)

OBJECTIVES OF TPM

The primary objectives of Total Productive Maintenance are to ensure that equipment
operates at its maximum efficiency and to foster a culture of collective responsibility. TPM
emphasizes employee involvement, skill development, and continuous improvement. Specific
objectives include:

1. Maximizing Overall Equipment Effectiveness (OEE): Achieving high performance

by reducing downtime, defects, and speed losses.
2. Eliminating Losses: Addressing six major losses: breakdowns, setup/adjustments,
minor stoppages, reduced speed, defects, and startup losses.
3. Improving Workplace Safety: Ensuring that all equipment and processes adhere to
stringent safety standards.
4. Fostering Employee Ownership: Encouraging operators to take responsibility for
basic maintenance, enhancing their skills and commitment.
5. Sustaining Long-Term Efficiency: Integrating maintenance practices into every
aspect of the organization to ensure sustained results.

EIGHT PILLARS OF TPM

The eight pillars of TPM serve as the foundation for its successful implementation, each
targeting specific aspects of operational efficiency:

1. Autonomous Maintenance:
o Empowers operators to handle basic maintenance tasks like cleaning,
lubrication, and inspection.
o Reduces reliance on specialized maintenance teams for routine activities.
o Benefits: Increases operator knowledge and reduces downtime.
o Challenges: Requires extensive training and monitoring.

2. Planned Maintenance:
o Focuses on scheduling maintenance activities based on equipment usage and
historical data.
o Minimizes unexpected breakdowns by proactively addressing wear and tear.
 o Benefits: Reduces emergency repairs and improves machine reliability.
o Challenges: Initial setup and data collection can be resource-intensive.

3. Quality Maintenance:
o Ensures that equipment produces defect-free outputs by maintaining optimal
conditions.
o Uses root cause analysis to identify and eliminate sources of defects.
o Benefits: Improves product quality and reduces waste.
o Challenges: Demands continuous monitoring and analysis.

4. Focused Improvement:
o Encourages cross-functional teams to identify and solve chronic inefficiencies.
o Targets specific problem areas to achieve rapid and measurable improvements.
o Benefits: Drives innovation and enhances teamwork.
o Challenges: Requires sustained commitment and collaboration.

5. Early Equipment Management:

o Integrates maintenance considerations into the design and procurement of new
equipment.
o Reduces startup issues and ensures maintainability from the outset.
o Benefits: Lowers lifecycle costs and speeds up implementation.
o Challenges: Involves higher initial coordination with vendors and designers.

6. Training and Education:

o Enhances employee skills to ensure that they can handle maintenance tasks
effectively.
o Builds a knowledgeable workforce capable of troubleshooting and optimizing
processes.
o Benefits: Reduces skill gaps and enhances job satisfaction.
o Challenges: Requires time and financial investment.

7. Safety, Health, and Environment (SHE):

o Promotes a safe, healthy, and eco-friendly work environment.
o Integrates safety practices into all maintenance activities to prevent accidents.
o Benefits: Ensures regulatory compliance and boosts employee morale.
 o Challenges: Needs continuous vigilance and updates to safety protocols.

8. Office TPM:
o Extends TPM principles to administrative functions to streamline workflows
and reduce inefficiencies.
o Improves coordination between operational and support departments.
o Benefits: Enhances organizational efficiency.
o Challenges: Difficult to quantify improvements in administrative settings.

ADVANTAGES OF TPM

1. Increased Productivity:
o Reduces equipment downtime, leading to higher production levels.
o Ensures equipment operates at optimal efficiency.

2. Cost Savings:
o Minimizes repair costs through proactive maintenance.
o Reduces waste and rework by ensuring consistent quality.

3. Employee Engagement:
o Encourages active participation and skill development among employees.
o Fosters a sense of ownership and accountability.

4. Improved Safety:
o Reduces workplace accidents through systematic safety measures.
o Ensures compliance with legal and environmental standards.

5. Better Asset Utilization:

o Extends the life of machinery and reduces the need for frequent replacements.
o Enhances return on investment in equipment.
DISADVANTAGES OF TPM

1. High Initial Investment:

o Requires significant resources for training, equipment upgrades, and cultural
transformation.
o May deter small businesses with limited budgets.

2. Time-Consuming Implementation:
o Establishing a TPM program and achieving noticeable results takes time.
o Demands sustained commitment from all levels of the organization.

3. Cultural Resistance:
o Employees and management may resist adopting new practices and
responsibilities.
o Overcoming this resistance requires strong leadership and continuous
communication.

4. Resource-Intensive:
o Involves additional work for employees already managing regular tasks.
o Needs skilled personnel for effective implementation and monitoring.

5. Complexity in Large Organizations:

o Coordinating TPM across multiple departments and facilities can be
challenging.
o Requires robust systems to manage and track progress.
CONCLUSION

Maintenance management is an indispensable aspect of organizational success, ensuring that

machinery and infrastructure operate efficiently and safely. By understanding the various
functions and types of maintenance, businesses can craft tailored strategies to minimize costs,
enhance productivity, and foster growth. A well-balanced approach that combines preventive,
predictive, and condition-based maintenance can deliver optimal results, supporting both
immediate operations and long-term goals. Ultimately, effective maintenance management
drives competitiveness, safety, and reliability in today’s fast-paced industrial landscape.