INTRODUCTION TO

MAINTENANCE
 INTR ODUCTION

 Plant maintenance is an Importantservice function of an

efficient production system.
 It helps in maintaining and increasing the operational
efficiency of plant facilities.
 Maintenance is the procedure of finding the faults in any
equipment/Machine and also removal of fault.
 I t may be before the breakdown or after the breakdown.
 Plant maintenance usually refers to the methods, strategies,
and practices used to keep an industrial factory running
efficiently. This can include anything from regular checks of
equipment to make sure they are functioning properly.
 T h e general aim of plant maintenance is to create a
productive working environment that is also safe for
workers.
 FAILURE

• Failure – inability to produce work in

appropriate manner
• Equipment / machine failure on production
floor – worn out bearing, pump, pressure
leaks, broken shaft, overheated machine
etc.
• Equipment failure in office – failure of power
supply, air-conditioned system, computer
network, photocopy machine
• Vehicle failure – brake, transmission, engine,
cooling system
MAINTENANCE IN SERVICE INDUSTRY

• Hospital
• Restaurants
• Transport companies
• Banks
• Hotels and resorts
• Shopping malls / retail
• Gas station
 MAINTENANCE IN
MANUFACTURING COMPANIES
• Electronic
• Automotive
• Petrochemicals
• Refinery
• Furniture
• Ceramics
• Food and beverages
 OBJECTIVES

• Minimize loss of productive time

• Minimize repair time & cost
• Keep productive assets in working
condition
• Minimize accidents
• Minimize total maintenance cost
• Improve quality of products
 IMPORTANCE

• Dependability of service
• Assured quality
• Prevent equipment failure
• Cost control
• Huge investment in equipment
 PROBLEMS IN MAINTENANCE

• Lack of management attention to

maintenance
• Little participation by accounting in
analyzing and reporting costs
• Difficulties in applying quantitative analysis
• Difficulties in obtaining time and cost
estimates for maintenance works
• Difficulties in measuring performance
 PROBLEMS EXIST DUE TO

• Failure to develop written objectives and

policy
• Inadequate budgetary control
• Inadequate control procedures for work
order, service requests etc.
• Infrequent use of standards
• To control maintenance work
• Absence of cost reports to aid maintenance
planning and control system
 MAINTENANCE OBJECTIVES

• Must be consistent with the goals of production

(cost, quality, delivery, safety)
• Must be comprehensive and include specific
responsibilities
 MAINTENANCE COSTS

• Cost to replace or repair

• Losses of output
• Delayed shipment
• Scrap and rework
 AREAS OF MAINTENANCE

1. Civil maintenance- Building construction and

maintenance, maintaining service facilities
2. Mechanical Maintenance- Maintaining machines
and equipments, transport vehicles, compressors
and furnaces.
3. Electrical Maintenance- Maintaining electrical
equipments such as generators, transformer,
motors, telephone systems, lighting, fans, etc.
NATURE OF MAINTENANCE
PROBLEM
 GENERAL CLASSIFICATION
MAINTENANCE PROBLEM
• Mechanical Failure
• Worn out bushes and bearings and other moving
parts. Fatigue of machine members
• Creep of material at high temp
• Excessive forced vibration, misalignments etc.
• Thermal Failure
• Overheating of the component
• Lack of lubrication
• Inadequate of cooling
• Electrical insulation failure
• Chemical Failure
• Highly corrosive fluids containing abrasive particles Failure of
protective linings like glass , rubber etc.
 CLASSIFICATION MAINTENANCE
PROBLEM BASED ON TIME SPAN
 S h o r t run productionproblem
Maintenance problem which are carried out in a sort period of time are known as short run
production system. It may be hourly, daily
,weekly and monthly.
Example:-
Hourly- inspection of correct lubricant, level of coolant, sharpness of cutting tool.
Daily- cleaning of m/c, tightening of nuts, correct cooling, inspection of various
indicators, minor adjustment of parts.
Weekly- Major adjustment, lubrication, tightening of parts.
Monthly- checking for insulation, corrosion, safety guards, checking of worn-out
and distorted parts.
 TYPES OF MAINTENANCE

• Breakdown maintenance or corrective

maintenance
• Preventive maintenance
• Predictive maintenance
• Routine maintenance
• Planned/Scheduled maintenance
BREAKDOWN MAINTENANCE

• Occurs when there is a work stoppage due to

machine breakdown
• Maintenance becomes repair work
• Seeks to get the equipment back into operation
as quickly as possible
• To control the investment in replacement spare
machines.
DISADVANTAGES OF CORRECTIVE
MAINTENANCE
• Breakdown generally occurs inappropriate times
leading to poor and hurried maintenance
• Excessive delay in production & reduces output
• Faster plant deterioration
• Increases chances of accidents and less safety
for both workers and machines
• More spoilt materials
• Direct loss of profit
• Can not be employed for equipments regulated
by statutory provisions e.g. cranes, lift and hoists
etc
PREVENTIVE MAINTENANCE (PM)

• Principle – “Prevention is better than cure”

• Procedure - Stitch-in-time
• It
• locates weak spots of machinery and
equipments
• provides them periodic/scheduled inspections
and minor repairs to reduce the danger of
unanticipated breakdowns
• Preventive management

It is undertaken before the need arises and aims to

minimize the possibility of un -anticipated
production interruption or major breakdowns
 ADVANTAGES OF PM

• Advantages:
• Reduces break down and thereby down time
• Lass odd-time repair and reduces over time of
crews
• Greater safety of workers
• Lower maintenance and repair costs
• Less stand-by equipments and spare parts
• Better product quality and fewer reworks and
scraps
• Increases plant life
• Increases chances to get production incentive
bonus
 PREDICTIVE (CONDITION-BASED)
MAINTENANCE
• In predictive maintenance, machinery
conditions are periodically monitored and
this enables the maintenance crews to take
timely actions, such as machine adjustment,
repair or overhaul

• It makes use of human sense and other

sensitive instruments, such as
• audio gauge, vibration analyzer, amplitude
meter, pressure, temperature and resistance strain
gauges etc.
PREDICTIVE MAINTENANCE (CONTD.)

• Unusual sounds coming out of a rotating equipment

predicts a trouble
• An excessively hot electric cable predicts a trouble
• Simple hand touch can point out many unusual
equipment conditions and thus predicts a trouble
 ROUTINE MAINTENANCE

• this includes activities such as periodic inspection,

cleaning, lubrication and repair of production
equipments after their service life.
SCHEDULED MAINTENANCE
• Scheduled maintenance is a stitch-in-time
procedure and incorporates
• inspection
• lubrication
• repair and overhaul of equipments
• If neglected can result in breakdown
• Generally followed for:
• overhauling of machines
• changing of heavy equipment oils
• cleaning of water and other tanks etc.
 CONTROL OF MAINTENANCE

1. Authorized by an official
2. Maintenance schedule
3. Issue materials against proper
authorization
4. Maintenance budgets
5. Equipment records
 MAINTENANCE SCHEDULING:

Scheduling refers to timing and sequences of

operations.

It is an important segment of the production planning

& control activity as well as the service operations
like plant maintenance
 IMPORTANCE OF SCHEDULING:

• Facilitates optimum use of highly paid maintenance

staff

• Equipments can be utilized effectively

• Eliminates undue interruptions in the production flow

• Eliminates chances of sudden breakdown

• Facilitates proper sequence in maintenance service

 TOTAL PRODUCTIVE
MAINTENANCE (TPM)
 Tot al productive maintenance (TPM) originated in Japan in
1971 as a method for improved machine availability through
better utilization of maintenance and production resources
 I t can be considered as the medical science of machines.
 Tot al Productive Maintenance (TPM) is a maintenance
program which involves a newly defined concept for
maintaining plants and equipment.
 T h e goal of the TPM program is to markedly increase
production while, at the same time, increasing employee
morale and job satisfaction.
 T P M brings maintenance into focus as a
necessary and vitally important part of the
business.
 It is no longer regarded as a non-profit activity.
Down time 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.
 WHY TPM
T P M was introduced to achieve the followingobjectives.
 Avoid wastage in a quickly changing economic environment.
 Producing goods without reducing product quality.
 Reduce cost.
 Produce a low batch quantity at the earliest possible time.
 Goods send to the customers must be non defective.