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Fleet Maintenance Management

MV 7121
Col (Prof) James K Varkey
24-03-2015

Fleet Maintenance Management

Syllabus
1. Introduction to Fleet Maintenance
2. Theory of Failure and Reliability
3. Maintenance Operation and Control
4. Vehicle and Equipment Replacement Strategy
5. Vehicle Maintenance Policy and Strategy
6. Vehicle Maintenance Programme
7. Vehicle Maintenance Planning
8. Maintenance Productivity
9. Implementation Steps of PM
10. Computerized Vehicle Maintenance Management
11. Total Productive Maintenance
12. Reliability Cantered Maintenance

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Vehicle Maintenance Policy and Strategy

Revision

Integrated logistics support concept

Types of maintenance
Stages of maintenance
Maintenance on the move
Decentralized maintenance detachments
Repair of a vehicle when battle casualty
Mine Causality Repair Team

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Vehicle Maintenance Program

Elements of planned maintenance
Plan administration
Facility inventory
Identification of equipment
Facility register
Maintenance schedule
Job specification
Maintenance program
Program control

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Vehicle Maintenance Program

Elements of planned maintenance

Introduction
The main objective of maintenance management is to increase availability at
minimum costs. It is said that every maintenance intervention scheduled
earlier or later than the optimal time increases the maintenance cost
As we have seen, on the one hand an excess of maintenance activity implies
high total costs, on the other hand a scarce maintenance activity determines a
higher probability of failure and, hence, greater total cost due to emergency
interventions.
Therefore, in order to select the best maintenance policy to perform an
attentive analysis of the failure mode, of the consequential costs, and of
operational convenience and practicality should be carried out.
Breakdown maintenance is convenient when the cost of failure is low, the cost
of maintenance is high, and the rate of failure does not increase with time. On
the contrary, preventive maintenance or corrective maintenance should be
chosen when the cost of failure is high and the rate of failure increases with
time.

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Vehicle Maintenance Program

Elements of planned maintenance

Plan Administration
As for the costs of the different maintenance policies, the administration should
take into account not only visible costs, such as labour, materials, services, and
maintenance overhead costs, but also hidden costs, which are more difficult to
detect and measure, such as operational interruption losses, time losses and
customer dissatisfaction.
The difficulty of carrying out costs and benefits analysis for the different
maintenance policies, considering both visible and hidden costs and their effects
on vehicle availability, points out the need of maintenance administration for
planning and control systems that support them in the policy design process.
Such activity should help maintenance administration to evaluate the effects of
the different policies on the performance of the maintenance system as a whole.

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Vehicle Maintenance Program

Elements of planned maintenance

Plan Administration
The feedback loop analysis should focus on four correlated areas:
- fleet management,
- maintenance scheduling,
- maintenance capacity management,
- service management.
For each of the four administrative areas identified above are the
related policy levers and the administration should analyze their
impact on the performance of the maintenance system by also
considering financial and inventory aspects and service quality
indicators.

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Vehicle Maintenance Program

Elements of planned maintenance
Maintenance plan and Schedule:
A document that outlines the management and
technical procedure to be employed to maintain the
vehicles and equipment; usually describes facilities,
tools, schedules, and resources.

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Vehicle Maintenance Program

Elements of planned maintenance

A maintenance department is expected to perform a wide range of

functions including:
Planning and repairing vehicles and equipment to acceptable
standards.
Performing preventive maintenance; more specifically, developing
and implementing a regularly scheduled work program for the
purpose of maintaining satisfactory vehicle/equipment operation as
well as preventing major problems.
Preparing realistic budgets that detail maintenance personnel and
material needs.
Managing inventory to ensure that parts/materials necessary to
conduct maintenance tasks are readily available.
Keeping records on equipment, services, etc.

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Vehicle Maintenance Program

Elements of planned maintenance

Developing effective approaches to monitor the activities of

maintenance staff.

Developing effective techniques for keeping operations

personnel, upper-level management, and other concerned
groups aware of maintenance activities.
Training maintenance staff and other concerned individuals to
improve their skills and perform effectively.
Reviewing plans for new facilities, installation of new equipment,
etc.
Implementing methods to improve workplace safety and
developing safety education-related programs for maintenance
staff.

Developing contract specifications and inspecting work

performed by contractors to ensure compliance with contractual
requirements

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Vehicle Maintenance Progam

Elements of Planned Maintenance.

One of the first considerations in planning a maintenance organization
is to decide whether it is advantageous to have a echelon based
maintenance system. Generally for defence services an echelon based
system serves well. Some of the benefits echelon maintenance are as
follows:
Benefits
More efficient compared to centralized maintenance
Fewer maintenance personnel required
More effective line supervision
Greater use of special equipment and specialized maintenance
persons
Permits procurement of more modern facilities
Generally allows more effective on-the-job training.

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Vehicle Maintenance Program

Elements of planned maintenance

A nine-step approach for managing a maintenance schedule
effectively is presented below:
Identify existing deficiencies.
Set maintenance goals. These goals take into consideration
existing deficiencies and identify targets for improvement.
Establish priorities.
Establish performance measurement parameters. Develop a
quantifiable measurement for each set goal.
Establish short- and long-range plans.
Document both long- (yearly)and short-range (monthly) plans and
forward copies to all concerned.

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Vehicle Maintenance Program

Elements of planned maintenance

Implement plan.
Report status. Preparing report periodically and forward it to all
concerned. The report should contain each objective identified and
scheduled and potential slippage of the schedule and associated
causes.
Examine progress at Regular Intervals.
Review progress at the end of each year with respect to stated goals.
Develop a new plan for the following year by considering the goals
identified in the long-range plan and adjustments made to the previous
years planned schedule, resources, costs, and so on.

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Vehicle Maintenance Program

Elements of Planned Maintenance

Maintenance Policy and Program
A maintenance policy is one of the most important
effective maintenance management. It is essential for
operations and a clear understanding of the
management program, regardless of the size of a
organization.

elements of
continuity of
maintenance
maintenance

Usually, maintenance organizations have manuals containing items

such as policies, programs, objectives, responsibilities, and authorities
for all levels of supervision, reporting requirements, useful methods
and techniques, and performance measurement indices.

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Vehicle Maintenance Program

Elements of Planned Maintenance

Material Control, Facility and Inventory

Past experience indicates that, on average, material costs account for
approximately 30 to 40% of total direct maintenance costs.
Efficient utilization of personnel depends largely on effectiveness in
material coordination. Material problems can lead to false starts,
excess travel time, delays, unmet due dates, etc. Steps such as job
planning, coordinating with purchasing, coordinating with stores,
coordination of issuance of materials, and reviewing the completed
job can help reduce material related problems.

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Vehicle Maintenance Program

Elements of Planned Maintenance

Job Specification
A work order and job specification authorizes and directs the
maintenance agency to perform a given task. A well-defined work order
and job specification system should cover all the maintenance jobs
requested and accomplished, whether repetitive or one-time jobs. The
work order system is useful for management in controlling costs and
evaluating job performance.
Although the type and size of the work order can vary from one
maintenance organization to another, a work order should at least
contain information such as requested and planned completion dates,
work description and its reasons, planned start date, labor and material
costs, item or items to be affected, work category (preventive
maintenance, repair, installation, etc.), and appropriate approval
signatures.

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Vehicle Maintenance Progam

Elements of Planned Maintenance

Equipment Records/ Register
Equipment records play a critical role in effectiveness and efficiency
of the maintenance organization. Usually, equipment records are
grouped under four classifications: maintenance work performed,
maintenance cost, inventory, and parts replaced. The maintenance
work performed category contains chronological documentation of all
repairs and preventive maintenance (PM) performed during the
items service life to date. The maintenance cost category contains
historical profiles and accumulations of labor and material costs by
item.
Equipment records are useful when procuring new items/equipment
to determine operating performance trends, troubleshooting
breakdowns, making replacement or modification decisions,
investigating incidents, identifying areas of concern, performing
reliability and maintainability studies, and conducting life cycle cost
and design studies.

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Vehicle Maintenance Progam

Elements of planned maintenance

Maintenance Schedule and Job Specification

Job planning is an essential element of the effective maintenance
management. A number of tasks may have to be performed prior to
commencement of a maintenance job like:
Procurement of parts,
Tools, and materials,
Coordination and delivery of parts
Identification of methods and sequencing,
Coordination with other departments,
Manpower detailing
Securing safety permits.

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Vehicle Maintenance Program

Mathematical Model for Optimum Preventive Maintenance

Preventive Maintenance (PM) is an important component of a
maintenance activity. Within a maintenance organization it usually
accounts for a major proportion of the total maintenance effort.
PM may be described as the care and servicing by individuals involved
with maintenance to keep vehicle/equipment in satisfactory operational
state by providing for systematic inspection, detection, and correction of
incipient failures either prior to their occurrence or prior to their
development into major failure.
Some of the main objectives of PM are to: enhance capital equipment
productive life, reduce critical equipment breakdowns, allow better
planning and scheduling of needed maintenance work, minimize
production losses due to equipment failures, and promote health and
safety of maintenance personnel.

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Vehicle Maintenance Program

Mathematical Model for Optimum Preventive Maintenance

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Vehicle Maintenance Program

Mathematical Model for Optimum Preventive Maintenance

1. Inspection: Periodically inspecting materials/items to determine their
serviceability by comparing their physical, electrical, mechanical, etc.,
characteristics (as applicable) to expected standards
2. Servicing: Cleaning, lubricating, charging, preservation, etc., of
items/ materials periodically to prevent the occurrence of incipient
failures
3. Calibration: Periodically determining the value of characteristics of
an item by comparison to a standard; it consists of the comparison of
two instruments, one of which is certified standard with known accuracy,
to detect and adjust any discrepancy in the accuracy of the
material/parameter being compared to the established standard value

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Vehicle Maintenance Program

Mathematical Model for Optimum Preventive Maintenance

4. Testing: Periodically testing or checking out to determine
serviceability and detect electrical/mechanical-related degradation
5. Alignment: Making changes to an items specified variable
elements for the purpose of achieving optimum performance
6. Adjustment: Periodically adjusting specified variable elements of
material for the purpose of achieving the optimum system
performance
7. Installation: Periodic replacement of limited-life items or the items
experiencing time cycle or wear degradation, to maintain the specified
system tolerance

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Vehicle Maintenance Program

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Vehicle Maintenance Progam

Elements of planned maintenance
Plan administration

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Vehicle Maintenance Progam

Elements of planned maintenance
Plan administration