Maintenance of Machinery and

Installation (MEng5311)
Adama Science and Technology University
School of Mechanical, Chemical and Materials Engineering

Department of Mechanical Engineering

 Chapter 1

Introduction
 Background
 Maintenance
 Maintenance Engineering Objectives
 Maintenance Term and Definition
 BACKGROUND
• Since the Industrial Revolution, maintenance of engineering equipment in the field has been a
challenge. Although impressive progress has been made in maintaining equipment in the field in an
effective manner, maintenance of equipment is still a challenge due to factors such as size, cost,
complexity, and competition.

• Needless to say, today’s maintenance practices are market driven, in particular for the
manufacturing and process industry, service suppliers, and so on.

• An event may present an immediate environmental, performance, or safety implication. Thus,

there is a definite need for effective asset management and maintenance practices that will
positively influence critical success factors such as safety, product quality, speed of innovation,
price, profitability, and reliable delivery.
• Each year billions of dollars are spent on equipment maintenance around the world.

• Over the years, many new developments have taken place in this area.

• The terms “maintenance” and “maintenance engineering” may mean different things to
different people.

• For example, the U.S. Department of Defense sees maintenance engineering as a

discipline that assists in acquisition of resources needed for maintenance, and provides
policies and plans for the use of resources in performing or accomplishing maintenance.

• In contrast, maintenance activities are viewed as those that use resources in physically
performing those actions and tasks attendant on the equipment maintenance function for
test, servicing, repair, calibration, overhaul, modification, and so on.
 Definition of Maintenance

• Maintenance:

• All actions appropriate for retaining an item/part/equipment in, or

restoring it to, a given condition.

• Maintenance engineering:
• The activity of equipment/item maintenance that develops concepts, criteria, and
technical requirements in conception and acquisition phases to be used and maintained in
a current status during the operating phase to assure effective maintenance support of
equipment.
• Is an analytical function as well as it is deliberate and methodical
• In engineering; actions are necessary for retaining or restoring a piece of equipment,
machine or system to the specified operable condition to achieve its maximum useful life.

• Maintenance Engineering is the discipline and profession of applying engineering

concepts to the optimization of equipment, procedures, and departmental budgets to
achieve better maintainability, reliability, and availability of equipment.

• Maintenance, and hence maintenance engineering, is increasing in importance due to

rising amounts of equipment, systems, machineries and infrastructure.

• Since the Industrial Revolution; devices, equipment, machinery and structures have
grown increasingly complex, requiring a host of personnel, vocations and related systems
needed to maintain them.
• Maintenance management is the process of overseeing maintenance
resources, so that the organization does not experience downtime from broken
equipment or waste money on inefficient maintenance procedures.

• Maintenance management software (MMS) programs can assist with the

process.

• The primary objectives of maintenance management are to schedule work

efficiently, control costs and ensure regulatory compliance.
 Maintenance Terms and Definitions

• Preventive maintenance:
• All actions carried out on a planned, periodic, and specific schedule to keep an
item/equipment in stated working condition through the process of checking and
reconditioning to forestall or lower the probability of failures or an
unacceptable level of degradation

• Corrective maintenance:
• The unscheduled maintenance or repair to return items/equipment to a defined
state and carried out because maintenance persons or users perceived
deficiencies or failures.
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 Maintenance Terms and Definitions
• Predictive maintenance:
• The use of modern measurement and signal processing methods to accurately diagnose
item/equipment condition during operation.

• Maintenance concept:
• A statement of the overall concept of the item/product specification or policy that controls
the type of maintenance action to be employed for the item under consideration.

• Maintenance plan:
• A document that outlines the management and technical procedure to be employed to maintain an item;
usually describes:
• facilities, tools, schedules, and resources.
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 Maintenance Terms and Definitions

• Reliability:
• The probability that an item will perform its stated function satisfactorily for the
desired period when used per the specified conditions.

• Maintainability:
• The probability that a failed item will be restored to adequately working condition.

• Active repair time:

• The component of downtime when repair persons are active to effect a repair.

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 Maintenance Terms and Definitions

• Mean time to repair (MTTR):

• A figure of merit depending on item maintainability equal to the mean item repair time.

• Overhaul:
• A comprehensive inspection and restoration of an item or a piece of equipment to an acceptable
level at a durability time or usage limit.

• Quality:
• The degree to which an item, function, or process satisfies requirements of customer and user.

• Inspection:
• The qualitative observation of an item’s performance or condition.
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 Objectives of Maintenance

Even though maintenance engineering and maintenance have the same end objective or goal (i.e., mission-ready
equipment/item at minimum cost), the environments under which they operate differ significantly.

More specifically, maintenance engineering is an analytical function as well as it is deliberate and methodical.
Nonetheless, the contributing objectives of maintenance engineering include:

Improve maintenance operations,

 Reduce the amount and frequency of maintenance,

 Reduce the effect of complexity,

 Reduce the maintenance skills required,

Reduce the amount of supply support

 Establish optimum frequency and extent of preventive maintenance to be carried out,

Improve and ensure maximum utilization of maintenance facilities, and improve the maintenance organization.
All over the world, industries have various ways to organize maintenance activities, namely;
Planned,
Unplanned,
Preventive,
Corrective, Or
Predictive Maintenance.

The primary objective is arrived at achieving maximum plant availability at minimum cost,
that is:

To prevent breakdown of equipment,

To prolong the life span of equipment,
 To restore equipment to acceptable condition with minimum delay after an eventual
breakdown.
Generally, the objectives of maintenance should be consistent with and subordinate to
production goals.

The relation between maintenance objectives and production goals is reflected in the
action of keeping production machines and facilities in the best possible condition.

 Maximising production or increasing facilities availability at the lowest cost and at

the highest quality and safety standards.

Reducing breakdowns and emergency shutdowns.

Optimising resources utilisation.

 Reducing downtime.

 Improving spares stock control.

 Improving equipment efficiency and reducing scrap rate.

 Minimising energy usage.

 Optimising the useful life of equipment.

 Providing reliable cost and budgetary control.

 Identifying and implementing cost reductions.

 PLANT

M Reducing Breakdowns
Maximising Production
A
I
Reducing Downtime
Minimising Energy Usage N
T
Optimising Useful Life of E Improving Equipment Efficiency
Equipment N
A
Providing Budgetary Control N Improving Inventory Control

C
Optimising Resource Utilisation E Implementing Cost Reduction

Figure 1: Objectives of Maintenance