Industrial Maintenance

1.
Concepts of Maintenance
Maintenance
Definition

Maintenance refers to the activities carried out to keep equipment and systems in working
order. It involves regular inspections, repairs, and replacements to ensure optimal
performance and prevent unexpected failures.

Operations Management BMA-210

Maintenance
Importance
Ensures Reliability: Regular maintenance helps in maintaining the reliability of equipment,
reducing the likelihood of unexpected breakdowns.
Enhances Safety: Proper maintenance ensures that equipment operates safely, protecting
workers and preventing accidents.
Increases Efficiency: Well-maintained equipment operates more efficiently, leading to
better productivity and lower operational costs.
Extends Equipment Life: Regular maintenance can extend the lifespan of equipment,
delaying the need for costly replacements.

Operations Management BMA-210

Maintenance
Objectives
Minimize Downtime: Reduce the amount of time equipment is out of service due to repairs
or maintenance activities.
Optimize Performance: Ensure that equipment operates at peak efficiency and
effectiveness.
Control Costs: Manage maintenance activities in a cost-effective manner, balancing the
costs of maintenance with the benefits of improved performance and reliability.
Ensure Compliance: Adhere to safety, environmental, and regulatory standards through
proper maintenance practices.

Operations Management BMA-210

Maintenance
Types
Preventive Maintenance: Scheduled maintenance activities aimed at preventing equipment
failures before they occur.
Corrective Maintenance: Repairs and maintenance activities carried out after a failure has
occurred to restore equipment to its operational state.
Predictive Maintenance: Using data and analytics to predict potential failures and address
them proactively before they happen.

Operations Management BMA-210

Maintenance
Key Maintenance Strategies
Time-Based Maintenance: Maintenance activities are scheduled at regular intervals based
on time or usage.
Condition-Based Maintenance: Maintenance activities are triggered by the actual condition
of the equipment, often monitored through sensors and inspections.
Reliability-Centered Maintenance (RCM): A comprehensive approach that focuses on
maintaining the functions of equipment rather than just the equipment itself, prioritizing
maintenance activities based on their impact on overall system reliability.

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2.
Organisation for Maintenance
Department
Maintenance
Hierarchical Structure:
Maintenance Manager: Oversees the entire maintenance function, sets policies, and
ensures alignment with organizational goals.
Supervisors/Team Leaders: Manage day-to-day operations, coordinate tasks, and
ensure compliance with maintenance schedules.
Technicians/Engineers: Perform the actual maintenance tasks, including inspections,
repairs, and installations.
Support Staff: Handle administrative tasks, inventory management, and
documentation.

Operations Management BMA-210

Maintenance
Functional Structure:
Preventive Maintenance Team: Focuses on scheduled maintenance activities to
prevent equipment failures.
Corrective Maintenance Team: Deals with repairs and corrective actions when
equipment fails.
Predictive Maintenance Team: Uses data and analytics to predict potential failures
and address them proactively.

Operations Management BMA-210

Maintenance
Coordination with Other Departments:
Production Department:
» Align maintenance schedules with production plans to minimize downtime.
» Communicate equipment issues and maintenance needs.
» Collaborate on continuous improvement initiatives.
Quality Control Department:
» Ensure maintenance activities do not compromise product quality.
» Address quality issues related to equipment performance.
» Participate in root cause analysis for equipment failures.
Operations Management BMA-210
Maintenance
Coordination with Other Departments:
Safety and Compliance Department:
Ensure maintenance activities comply with safety regulations.
Conduct safety audits and inspections.
Provide training on safety procedures and protocols.
Finance Department:
Manage maintenance budget and expenditures.
Approve procurement of maintenance supplies and services.
Analyze cost-effectiveness of maintenance activities.
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3.
Types of Maintenance
 Preventive Maintenance 14

Scheduled maintenance activities performed regularly to prevent equipment

failures and extend the lifespan of assets.

Examples Benefits Challenges

• Regular lubrication of • Reduces the likelihood of • Requires planning and
machinery. unexpected breakdowns. scheduling.
• Scheduled inspections • Improves equipment reliability • Can be costly if not managed
and cleaning. and performance. properly.
• Replacing worn-out • Extends the life of equipment. • May lead to unnecessary
parts before they fail. maintenance if not based on
actual equipment condition.

Operations Management BMA-210

 Breakdown Maintenance 15

Maintenance activities performed after equipment has failed to restore it to

operational condition.

Examples Benefits Challenges

• Repairing a machine • Simple to implement as it • Leads to unexpected downtime
after it has stopped requires no planning. and production losses.
working. • Can be cost-effective for non- • Can be more costly in the long
• Replacing a broken critical equipment. run due to emergency repairs.
component. • May result in safety hazards if
critical equipment fails.

Operations Management BMA-210

 Corrective Maintenance 16

Maintenance activities performed to correct identified issues and restore equipment

to its proper working condition.

Examples Benefits Challenges

• Fixing a malfunctioning • Addresses specific issues that • Requires regular inspections to
part identified during an can affect performance. identify issues.
inspection. • Can improve equipment • Can be time-consuming if
• Adjusting equipment efficiency and reliability. issues are complex.
settings to optimal • Helps in maintaining safety • May require specialized skills
levels. standards. and tools.

Operations Management BMA-210

 Predictive Maintenance 17

Maintenance activities based on the actual condition of equipment, using data and
analytics to predict potential failures.

Examples Benefits Challenges

• Using vibration analysis • Reduces unnecessary • Requires investment in
to detect bearing wear. maintenance activities. monitoring technology and
• Monitoring temperature • Improves equipment reliability data analysis.
and pressure to identify and performance. • Needs skilled personnel to
potential issues. • Can prevent catastrophic failures interpret data and make
by addressing issues early. decisions.
• Can be complex to implement
and manage.

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4.
Failure Analysis
Failure Analysis
Definition:
Failure analysis is the process of investigating and determining the root causes of equipment or system
failures. It involves examining the failed components, understanding the failure mechanisms, and
identifying corrective actions to prevent recurrence.

Importance:
• Helps in improving equipment reliability and performance.
• Reduces downtime and maintenance costs.
• Enhances safety by preventing similar failures in the future.
• Provides valuable insights for continuous improvement.

Operations Management BMA-210

Common Techniques
Root Cause Analysis (RCA):
A systematic method used to identify the underlying causes of a failure.

Steps:
• Identify the Problem: Clearly define the failure and its impact.
• Collect Data: Gather information about the failure, including when, where, and how it occurred.
• Analyze Data: Use tools like the 5 Whys, Fishbone Diagram (Ishikawa), or Fault Tree Analysis to identify
root causes.
• Implement Solutions: Develop and implement corrective actions to address the root causes.
• Monitor Results: Evaluate the effectiveness of the solutions and make adjustments as needed.

Operations Management BMA-210

Case Studies
Root Cause Analysis (RCA):
Manufacturing Equipment Failure
• Problem: Frequent breakdowns of a conveyor belt system.
• RCA Findings: Root cause identified as improper lubrication leading to bearing wear.
• Solution: Implemented a regular lubrication schedule and upgraded to higher-quality
bearings.
• Result: Reduced breakdowns and increased equipment uptime.

Operations Management BMA-210

Common Techniques
Failure Mode and Effects Analysis (FMEA):
A proactive tool used to identify potential failure modes, their causes, and effects on system performance.

Steps:
• Identify Failure Modes: List all possible ways a component or system can fail.
• Determine Effects: Assess the impact of each failure mode on system performance.
• Analyze Causes: Identify the root causes of each failure mode.
• Prioritize Risks: Rank failure modes based on their severity, occurrence, and detectability.
• Develop Actions: Implement actions to mitigate high-priority risks.

Operations Management BMA-210

Case Studies
Failure Mode and Effects Analysis (FMEA):
Electrical System Failure
• Problem: Intermittent power outages in a production facility.
• FMEA Findings: Identified potential failure modes such as faulty wiring, overloaded
circuits, and aging components.
• Solution: Upgraded electrical infrastructure, installed surge protectors, and conducted
regular inspections.
• Result: Improved system reliability and reduced power outages.

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5.
Maintenance Performance
Maintenance Performance
Key Performance Indicators (KPIs)
Mean Time Between Failures (MTBF):
• Definition: The average time elapsed between two consecutive failures of a system or
component.

𝑻𝒐𝒕𝒂𝒍 𝑶𝒑𝒆𝒓𝒂𝒕𝒊𝒏𝒈 𝑻𝒊𝒎𝒆

𝑴𝑻𝑩𝑭 =
𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑭𝒂𝒊𝒍𝒖𝒓𝒆𝒔
• Importance: Higher MTBF indicates better reliability and fewer breakdowns.

Operations Management BMA-210

Maintenance Performance
Key Performance Indicators (KPIs)
Overall Equipment Effectiveness (OEE):
• Definition: A comprehensive metric that evaluates how effectively equipment is being
used.

𝑻𝒐𝒕𝒂𝒍 𝑹𝒆𝒑𝒂𝒊𝒓 𝑻𝒊𝒎𝒆

𝑴𝑻𝑻𝑹 =
𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑹𝒆𝒑𝒂𝒊𝒓𝒔
• Importance: Lower MTTR indicates quicker repairs and reduced downtime.

Operations Management BMA-210

Maintenance Performance
Key Performance Indicators (KPIs)
Mean Time to Repair (MTTR):
• Definition: The average time required to repair a system or component and restore it to
operational condition.
• Components:
• Availability: The percentage of scheduled time that the equipment is available for operation.
• Performance: The speed at which the equipment operates as a percentage of its designed speed.
• Quality: The percentage of good units produced out of the total units produced.
𝑴𝑻𝑻𝑹 = 𝑨𝒗𝒂𝒊𝒍𝒂𝒃𝒊𝒍𝒊𝒕𝒚 × 𝑷𝒆𝒓𝒇𝒐𝒓𝒎𝒂𝒏𝒄𝒆 × 𝑸𝒖𝒂𝒍𝒊𝒕𝒚
• Importance: Higher OEE indicates better utilization and efficiency of equipment..

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5.
Methods to Improve Performance
Methods to Improve Performance
Regular Training and Development:
• Description: Provide ongoing training for maintenance staff to enhance their skills and knowledge.
• Benefits: Improves the quality of maintenance work and reduces the likelihood of errors.

Implementing Predictive Maintenance:

• Definition: Use data and analytics to predict potential failures and address them proactively.
• Benefits: Reduces unexpected breakdowns and extends equipment life.

Optimizing Spare Parts Inventory:

• Definition: Maintain an optimal inventory of spare parts to ensure quick repairs without overstocking.
• Benefits: Reduces downtime and minimizes inventory costs.

Operations Management BMA-210

Methods to Improve Performance
Using Maintenance Management Software:
• Description: Implement Computerized Maintenance Management Systems (CMMS) to plan, schedule,
and track maintenance activities.
• Benefits: Enhances organization, improves record-keeping, and facilitates data-driven decision-
making.

Conducting Regular Inspections and Audits:

• Definition: Perform routine inspections and audits to identify potential issues before they lead to
failures.
• Benefits: Helps in early detection of problems and ensures compliance with safety standards.

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5.
Replacement Policies of Machines
Factors Influencing Replacement Decisions
Age of Equipment:
• Older equipment may become less reliable and more costly to maintain.
• Technological advancements may render older machines obsolete.
Maintenance Costs:
• Increasing maintenance costs can indicate that replacement is more cost-effective.
• Frequent breakdowns and repairs can disrupt operations and increase downtime.
Performance and Efficiency:
• Newer machines may offer better performance and energy efficiency.
• Improved productivity and reduced operational costs can justify replacement.
Safety and Compliance:
• Ensuring equipment meets current safety and regulatory standards.
• Older machines may pose safety risks and fail to comply with updated regulations.

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6.
Types of Replacement Policies
Types of Replacement Policies
Age-Based Replacement:
• Definition: Replacing equipment after a predetermined period, regardless of its condition.
• Advantages:
• Simple to implement and plan.
• Ensures regular updates to equipment.

• Disadvantages:
• May lead to premature replacement of still-functional equipment.
• Does not account for the actual condition or performance of the equipment.

Operations Management BMA-210

Types of Replacement Policies
Condition-Based Replacement:
• Definition: Replacing equipment based on its actual condition and performance.
• Advantages:
• More cost-effective as it extends the useful life of equipment.
• Reduces the risk of unexpected failures by monitoring equipment health.

• Disadvantages:
• Requires investment in monitoring technology and regular inspections.
• More complex to manage and implement.

Operations Management BMA-210

Types of Replacement Policies
Economic Life Replacement:
• Definition: Replacing equipment when the total cost of owning and operating it is
minimized.
• Advantages:
• Balances maintenance and replacement costs for optimal economic benefit.
• Helps in making data-driven decisions.

• Disadvantages:
• Requires detailed cost analysis and forecasting.
• May be challenging to determine the precise economic life of equipment.

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6.
Types of Replacement Policies
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