Maintenance

Maintenance
Equipments are an important resource which is constantly used for adding

value to products. So, it must be kept at the best operating condition.
Otherwise, there will be excessive downtime and also interruption of
production if it is used in a mass production line. Poor working of
equipments will lead to quality related problems.
Types of maintenance
• Breakdown maintenance
• Preventive maintenance
• Predictive maintenance
Breakdown maintenance
Breakdown maintenance is basically the ‘run it till it breaks’ maintenance mode. No
actions or efforts are taken to maintain the equipment as the designer originally
intended to ensure design life is rea
Advantages
1. Involves low cost investment for maintenance.
2. Less staff is required.
Disadvantages
3. Increased cost due to unplanned downtime of equipment.
4. Increased labor cost, especially if overtime is needed.
5. 3. Cost involved with repair or replacement of equipment.
Preventive maintenance
Preventive maintenance can be defined as, “Actions performed on a time or machine-run-
based schedule that detect, preclude, or mitigate degradation of a component or system with
the aim of sustaining or extending its useful life through controlling degradation to an
acceptable level.”
Advantages
1. Cost effective in many capital intensive processes.
2. Flexibility allows for the adjustment of maintenance periodicity.
3. Increased component life cycle.
4. Energy savings.
5. Reduced equipment or process failure.
6. Estimated 12% to 18% cost savings over reactive maintenance program.
Disadvantages
1. Catastrophic failures still likely to occur.
2. 2. Labour intensive.
3. 3. Includes performance of unneeded maintenance.
4. 4. Potential for incidental damage to components in conducting unneeded maintenance
Predictive maintenance
• Predictive maintenance can be defined as “Measurements that detect
the onset of a degradation mechanism, thereby allowing causal
stressors to be eliminated or controlled prior to any significant
deterioration in the component physical state. Results indicate
current and future functional capability”.
• Advantages 1. Increased component operational life/availability. 2.
Allows for pre-emptive corrective actions. 3. Decrease in equipment
or process downtime. 4. Decrease in costs for parts and labour.
• Disadvantages 1. Increased investment in diagnostic equipment. 2.
Increased investment in staff training. 3. Savings potential not readily
seen by management.
Concept of Reliability in Maintenance
• Reliability is the probability of survival under a given operating
environment
MAINTENANCE PLANNING
• Planning of maintenance jobs basically deals with answering two
questions, ‘what’ and ‘How’ of the job; ‘what activities are to be
done?’ and ‘how those jobs and activities are to be done.
• Steps of Job Planning The main steps to be followed for proper job
planning are:
• 1. Knowledge base: It includes knowledge about equipment, job,
available techniques, materials and facilities.
• 2. Job investigation at site: It gives a clear perception of the total jobs.
• 3. Identify and document the work: Knowing the earlier two steps and
knowing the needs of preventive, predictive and other maintenance jobs.
• 4. Development of repair plan: Preparation of step by step procedures
which would accomplish the work with the most economical use of time,
manpower and material.
• 5. Preparation tools and facilities list indicating the needs of special tools,
tackles and facilities needed.
• 6. Estimation of time required to do the job with work measurement
technique and critical path analysis
KANBAN SYSTEM
Kanban (Japanese: 看板 , meaning signboard or billboard) is
a scheduling system for lean manufacturing and just-in-time
manufacturing (JIT). Taiichi Ohno, an industrial
engineer at Toyota, developed kanban to improve manufacturing
efficiency.
A goal of the kanban system is to limit the buildup of excess
inventory at any point in production. Kanban aligns inventory
levels with actual consumption.
Toyota's Six Rules
• Toyota has formulated six rules for the application of kanban:

1.Each process issues requests (kanban) to its suppliers when it consumes
its supplies.
2.Each process produces according to the quantity and sequence of
incoming requests.
3.No items are made or transported without a request.
4.The request associated with an item is always attached to it.
5.Processes must not send out defective items, to ensure that the finished
products will be defect-free.
6.Limiting the number of pending requests makes the process more sensitive
and reveals inefficiencies.
Kanban cards
• Kanban cards are a key component of kanban and they signal
the need to move materials within a production facility or to
move materials from an outside supplier into the production
facility. The kanban card is, in effect, a message that signals a
depletion of product, parts, or inventory. When received, the
kanban triggers replenishment of that product, part, or
inventory. Consumption, therefore, drives demand for more
production, and the kanban card signals demand for more
product—so kanban cards help create a demand-driven
system.
Enterprise recourse planning
• Enterprise resource planning (ERP) refers to a type of software that
organizations use to manage day-to-day business activities such
as accounting, procurement, project management, risk management
and compliance, and supply chain operations
Business value of ERP
• Improved business insight from real-time information generated by reports
• Lower operational costs through streamlined business processes and best practices
• Enhanced collaboration from users sharing data in contracts, requisitions, and
purchase orders
• Improved efficiency through a common user experience across many business
functions and well-defined business processes
• Consistent infrastructure from the back office to the front office, with all business
activities having the same look and feel
• Higher user-adoption rates from a common user experience and design
• Reduced risk through improved data integrity and financial controls
• Lower management and operational costs through uniform and integrated systems

Maintenance

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Maintenance

Equipments are an important resource which is constantly used for adding

• Toyota has formulated six rules for the application of kanban:

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