Maintenance and its types
Definition
Maintenance is defined as the combination of activities by which equipment or a system is kept
in, or restored to, a state in which it can perform its designated functions.
It is an important factor in product quality and can be used as a strategy for successful
competition.
Inconsistencies in production equipment operation result in excessive variability in the product
and, thus, cause defective output.
To produce a high level of quality, production equipment must operate within specifications that
are attainable by timely maintenance actions.
A system is a collection of components that work together toward a common objective.
Maintenance can be considered as a system with a set of activities carried out in parallel with
production systems.
A diagrammatic relationship among organizational objectives, the production process, and
maintenance is shown in figure below.
Organizational
objectives
Quality Quantity
Delivery
Production
Input process Output
Feedback
Production Maintenance Demand for
capacity process maintenance
Production systems are usually concerned with converting inputs such as raw materials, labor, & processes
into products that satisfy customer needs.
The primary output of a production system is finished products; a secondary output is failure of equipment.
This secondary output generates demand for maintenance.
The maintenance system takes this as an input and adds to it know-how, labor, and spares, and produces
equipment in good condition that provides capacity for production.
The overall primary goal of a production system is to maximize profits from the available market
opportunities, and its secondary goal is concerned with the economical and technical aspects of the
conversion process.
Maintenance systems assist in achieving these goals as well, by increasing profits and customer satisfaction.
These are achieved by minimizing plant downtime, improve quality, increasing productivity, and delivering
orders to customers in a timely fashion.
A maintenance system can be viewed as a simple input and output model.
The inputs to such a model are labor, management, tools, spares, equipment, and so forth,
and the output is equipment that is up, reliable, and well configured to achieve the
planned operation of the plant.
This enables us to optimize the resources for maximizing the output of a maintenance
system.
Planning, organizing and control are the activities needed to make a maintenance
system.
Planning Activities:
Planning activities generally include the following:
1. Maintenance philosophy
2. Maintenance load forecasting
3. Maintenance capacity
4. Maintenance organization
5. Maintenance scheduling
Maintenance Philosophy
The maintenance philosophy of a plant is basically to maintain a minimum level of maintenance staff
that is consistent with the optimization of production and plant availability without compromising safety.
To achieve this philosophy, the following strategies can play an effective role If applied in the right mix
and fashion:
1. Breakdown/corrective maintenance
2. preventive maintenance
a. time or use based preventive maintenance
b. condition based preventive maintenance
3. opportunity maintenance
4. fault finding
5. design modification
6. Overhaul
7. Replacement
Breakdown/corrective maintenance
This type of maintenance is only performed when the equipment is incapable of further
operation.
There is no element of planning for this type of maintenance
This is the case when the extra cost of other types of maintenance cannot be justified.
This type of strategy is sometimes referred to as a run-to-failure strategy. It is applicable
mostly to electronic component.
Time –or use –based preventive
maintenance
Preventive maintenance is any planned maintenance performed to counteract potential failures.
It could be implemented based on use or equipment condition .
Time -or use –based preventive maintenance is Performed on an hours-run or calendar basis. It needs a
high level of planning.
The specific routines to be carried out are known as well as their frequencies .
In determining the frequency, knowledge about failure distribution or equipment reliability is usually
needed .
Condition –based preventive
maintenance
Condition –based preventive maintenance is carried out on the
basis of the known condition of the equipment.
The condition of the equipment is determined by monitoring key
equipment parameters whose values are affected by the condition
of the equipment.
This strategy is also known as predictive maintenance.
Opportunity maintenance
This type of maintenance ,as the name implies ,is carried out when
the opportunity arises.
Such opportunities may arise during shut down periods of a
particular system and can be utilized for carrying out known
maintenance tasks.
Fault finding
Fault finding is an act or inspection performed to assess the level of
failure onset. An example of fault finding is checking the spare tire
of a car prior to taking a long trip.
Design Modification
Design modification is carried out to bring a piece of equipment to a currently
acceptable condition.
it involves improvement and occasionally manufacturing and capacity
expansion.
design modification usually requires coordination with engineering and other
Department within the organization.
Overhaul
Overhaul is the comprehensive examination and restoration of a piece of
equipment or its major components to an acceptable condition. This is usually a
major task.
Replacement
This strategy involves replacing the equipment instead of performing maintenance it
could be planned replacement or replacement upon failure.
Maintenance Load forecasting
Maintenance load forecasting is the process by which the maintenance
load is predicted .
The maintenance load in a given plant varies randomly and , among
other factors , can be a function of the age of the equipment , the rate of its
use , maintenance quality ,Climatic factors and the skills of maintenance
workers .
Maintenance Load forecasting is essential for achieving a desired level of
effectiveness and resource utilization , and, without it ,many maintenance
functions cannot be performed well.
Maintenance capacity planning
Maintenance capacity planning determines the resources needed to meet the demand for
maintenance work.
These resources include labor ,material ,spare parts ,equipment and tools .
Critical aspects of maintenance capacity include the numbers and skills of Craftsmen, required
maintenance tools and so on.
Because the maintenance load is a random variable , the exact number of various types of Craftsmen
cannot be determined.
Therefore , without reasonably accurate forecast of future maintenance world demand, it would not be
possible to perform proper long range capacity planning. To better utilize their labor resources ,
organizations tend to employ fewer Craftsman then there anticipated need, which is likely to result in a
backlog of uncompleted maintenance work.
This Backlog can be completed by letting the existing workers work overtime or by seeking outside
contractor assistance .
The backlog can also be cleared when maintenance load is less than the capacity .
Maintenance organization
Depending on the maintenance load , size of the plant , trade skills and so on ,
maintenance may be organized on a departmental area or central basis .
Each type of organization has its pros and cons .
In large organizations , decentralization of the maintenance function can
produce quicker response time and allow workers to become more familiar
with the problems of a particular section of the plant . However , the creation of
a number of small units tends to reduce the flexibility of the maintenance
system as a whole.
The range of skills available becomes reduced and labor utilization is usually
less then in a centralized maintenance unit . In some cases , a compromise
solution, called a cascade system , can be implemented .
Maintenance scheduling
Maintenance scheduling is the process of assigning resources and manpower for
jobs to be accomplished at certain times .
It is necessary to ensure that the workers , parts and materials required are
available before a maintenance task can be scheduled .
Critical equipment in a plant are those equivalent who's failure will shut down the
production process or endanger human life and safety .
Preventive Maintenance
Preventive maintenance is the preferred approach to asset
management:
It can prevent premature failure and reduce its frequency .
It can reduce the severity of failure and mitigate its consequences .
It can provide warning of an impending or incipient failure to allow
planned repair.
It can reduce the overall cost of asset management
Repair maintenance can be divided into 2 broad categories ;
Planned repair and unplanned repair.
planned repair implies,1st ,that all resources necessary to accomplish the task have
been preplanned and are available , and 2nd , that the work is to be performed
according to a set schedule .
Unplanned repair may have a set of standard instructions available ,may have the
necessary workers and parts nearby , or may be slotted into a maintenance schedule on
ad hoc basis, But does not meet both the preplanned and pre scheduled criteria.
Preventive maintenance is carried out to ensure equipment availability
and reliability .
Equipment availability can be defined as the probability of a piece of
equipment being able to operate whenever needed . Equipment
reliability is the probability that the equipment will be functioning at time t.
The aim of preventive maintenance is to maximize equipment availability
and reliability by carrying out planned maintenance , which commonly is
known as preventive maintenance .
It is the preferred approach relative to breakdown maintenance for four reasons
The frequency of premature failures can be reduced through proper lubrication,
adjustments ,cleaning and inspections triggered by performance measurement .
If the failure cannot be prevented , periodic inspection and measurement can
help to reduce the severity of the failure and it's possible domino effect on other
components of the equipment system , and there by mitigate the negative
consequences to safety , the environment or production throughput .
Where we can monitor the gradual degradation of a function or parameter,
Such as product quality or machine vibration, a warning of impending failure
may be detected.
Finally ,because an unplanned interruption is often extremely damaging to
production schedules and output, because the actual cost of an emerging
breakdown is higher than a planned one, and the quality of repair can suffer
under the pressure of an emergency , there are major direct and indirect cost
differences between preventive and planned maintenance , compared to
breakdown maintenance .
The most critical question in preventive maintenance is :
What task or series of tasks should be performed to prevent failure?
Clearly, if We understand the actual failure mechanism of the equipment , we can
then decide which tasks are logical to prevent failure and which ones are
irrelevant .
if the PM program requires changing the headlights on an auto mobile each
month, then that have an impact on the failure rate ?
most likely not , because the failure mechanism is not related to time, but to other
variables such as the distance the car is driven behind a large truck on a gravel
Road.
If the dominant failure mechanism is time based or due to wear, That is ,
if the probability of a failure gradually increases with time , age or usage ,
then the maintenance task may be time based . If however , the
probability of a failure is constant regardless of time ,age or usage , and
there is a gradual degradation from the onset of Failure , then the
maintenance task may be condition based .
time based tasks are warranted if the periodic restoration or component
replacement Restores the equipment to perform its intended function.
Condition based tasks, warranted when the failure prevention approach is
unknown, focus on measuring a parameter that indicates a deterioration or
degradation in the functional performance of the equipment . the measurements
and inspections themselves maybe regularly scheduled , but the restorative or
preventive tasks are not.
These measures can be related directly to machine operations , such as vibration
, running temperature , lubricating oil contaminants , or noise level, or can be
surrogate measure of machine operation, such as product quality , its dimensions
, wear patterns or composition .
Predictive Maintenance
Breakdown Maintenance
Total Productive Maintenance
Total predictive maintenance is a management approach to maintenance that focuses on
involving all employees in an organization in equipment improvement .
Key goals of total productive maintenance are :
maximize overall equipment effectiveness , which includes availability , process efficiency
and product quality .
take a systematic approach to reliability , maintainability and life cycle costs.
involve operations , materials management, maintenance, engineering and administration in
equipment management.
Involve all levels of management and workers .
improved equipment performance through small group activities and team performance .
In TPM , whenever equipment performs at a level less than required , the
performance loss is recorded and monitored.
These losses can be grouped into 6 categories :
break downs , setup and adjustments , idling and minor stoppages ,
Reduced speed , defects and yield losses .
•Breakdown account for a large percentage of total losses . Every attempt should be
Equipment Failure made to avoid them . To maximize equipment effectiveness , break downs must be
reduced to 0 by changing the attitude that breakdowns are inevitable .
•When production of a given product time ends and the equipment is adjusted to get
setup an adjustment downtime ready to produce another product type , there are losses due to setup downtime and
defective products. These losses can be reduced by reducing the setup time .
•production may be interrupted Because of a malfunction or a production machine being
IDLING and minor stoppages idle between products.
•The sources of these losses must be identified and eliminated . the elimination of minor
stoppages is an essential precondition for automated production
•These losses correspond to the difference between equipment design speed and the
Reduced Speed actual operating speed . Reduce speed may be due to mechanical problems and
Defective quality or may be imposed by the operator in fear of abusing the equipment .
•In other cases the optimal speed may not even be known .
•These are losses in quality caused by the equipment . The conditions causing the defect
Process Defects must be identified and eliminated .
•these are the startup losses occurring during the early stages of production from the
Reduced Speed beginning to its stabilization . improving equipment effectiveness requires that the losses
Be measured.
