Maintenance Management

Introductio
n

Shahriar Tanvir
Lecturer,
Industrial and Production Engineering (IPE).
Military Institute of Science and Technology (MIST).
Introduction
:
i. Plant maintenance is an important service function
of an efficient production system.
ii. I t helps in maintaining and increasing the
operational efficiency of plant facilities.
iii. Maintenance is the procedure of finding the faults
in any equipment/Machine and also removal of fault.
iv. I t may be before the breakdown or after the
breakdown.
v. Plant maintenance usually refers to the methods,
strategies, and practices used to keep an industrial
factory running efficiently. This can include
anything from regular checks of equipment to make
sure they are functioning properly.

vi. The general aim of plant maintenance is to create a

productive working environment that is also safe for
workers.
Maintenance Objectives :
i. To increase functional reliability of production
facilities .
ii. To maximize the useful life of the equipment .
iii. To maximize production capacity from the given
equipment .
iv. To minimize the total production cost.
v. To minimize the frequency of interruption in
production by educing breakdowns .
vi. To enhance the safety of the manpower.
Maintenance Objectives:
 Necessity of Maintenance Management :
i. Maintenance activities are related with repair, replacement
and service of components or some identifiable group of
components in a manufacturing plant so that it may
continue to operate at a specified ‘availability’ for a
specified period.
ii. Thus maintenance management is associated with the
direction and organization of various resources so as to
control the availability and performance of the industrial
unit to some specified level.
iii. Thus maintenance management may be treated as a
restorative function of production management which is
entrusted with the task of keeping equipment/machines and
plant services ever available in proper operating condition.
iv. The minimization of machine breakdowns and down time
v. Maintenance has been considered just to repair the faulty
equipment and put them back in order in minimum possible
time.
vi. In view of the utilization of mostly general
purpose/conventional machines with low production
output, the demands on maintenance function were not very
high. But with fast developments in the design,
development and mechanisms of control such as electronic,
NC and CNC in machine tools the manufacturing scenario
has changed a lot.
vii. The stringent control of dimensional tolerances and surface
finish of the product have increased the tendency to adopt
standardization and interchange-ability of parts/components
of machines.
viii.In the current production setups even a minor down time
Different type of maintenance :
Planned Maintenance :
In planned maintenance the maintenance action is
carried out with some fore thoughts, prior planning ,
record keeping and control action. These can be further
classified as :

i. Preventive Maintenance.
ii. Corrective Maintenance.
iii. Predictive Maintenance.
Preventive Maintenance :
i. It is based upon the principle that ‘prevention is better than
cure’.
ii. It is a set of activities that are performed on plant
equipment, machinery, and systems before the
occurrence of a failure in order to protect them and to
prevent or eliminate any degradation in their
operating conditions.
iii. Or the maintenance carried out at predetermined intervals
or according to prescribed criteria and intended to reduce
the probability of failure or the degradation of the
functioning and the effects limited.
iv. It has three types
i. Running maintenance.
ii. Scheduled maintenance.
 Running maintenance :
i. Running maintenance which includes those
maintenance activities that are carried out while the
machine or equipment is running.
ii. Example–lubrication, adjustment of nuts and screws,
tightening of loose nut and bolts.
 Scheduled Maintenance :
i. Scheduled Maintenance is any variety of scheduled
maintenance to an object or item of equipment.
ii. Specifically, Planned Maintenance is a scheduled
service visit carried out by a competent and suitable
agent, to ensure that an item of equipment is operating
correctly and to therefore avoid any unscheduled
breakdown and downtime.
iii. Good example of PM program is car maintenance.
After so many kilometers or miles oil should be
changed, parts renewed.
Shut Down Maintenance:
i. Which is a set of preventive maintenance activities
that are carried out when the production line is in total
stoppage situation.
ii. These are performed generally after three or six
months.
iii. These involves the inspection of plant items which are
known or suspected to occur.
Corrective maintenance :
i. In this type, actions such as repair, replacement, or
restore will be carried out after the occurrence of a
failure in order to eliminate the source of this failure
or reduce the frequency of its occurrence.
ii. It also include the different types of actions like
typical adjustment of redesign equipment.
iii. The difference between corrective maintenance and
preventive maintenance is that for the corrective
maintenance, the failure should occur before any
corrective action is taken.
iv. It is of two types
i. Breakdown maintenance
ii. Shut down maintenance
Breakdown Maintenance :
i. It is an emergency based policy in which the plant or
equipment is operated until it fails and then it is brought
back into running condition by repair.
ii. The maintenance staff locate any mechanical,
electrical or any other fault to correct it immediately.
iii. It is feasible for the small factories where
iv. There are few types of equipment.
v. Machine and equipments are simple and does not
require any specialist.
vi. Where sudden failure does not cause any serious
financial loss.
Predictive maintenance :
i. As the names implies it involves the prediction of the
failure before it occurs, identifying the root cause for
those failures symptoms and eliminating those causes
before they result in extensive damage of the
equipment.
ii. Type of maintenance performed continuously or at
intervals according to the requirements to diagnose
and monitor a condition or system. Also called
condition based maintenance.
Unplanned Maintenance :
i. Maintenance action which is carried out without
any fore thoughts or prior planning is called
unplanned maintenance.
ii. Emergency maintenance is one of the example of
unplanned maintenance.
iii. In this type of maintenance the maintenance action
is executed with the help of all available
maintenance resources in least possible time, without
any major time lag.
iv. Examples are gas leakage in chemical plant, fire
hazards, breakdown of boiler, turbine etc.
Nature of maintenance problem :
Maintenance can be classifies as follow :

 General classification of maintenance problems

i. Mechanical Failure
ii. Thermal Failure
iii. Chemical Failure

 Classification of maintenance problems based on

time span
i. Short Run Maintenance Problem
ii. Long Run Maintenance Problem
General classification Maintenance problem :
Mechanical Failure
i. Worn out bushes and bearings and other moving
parts.
ii. Fatigue of machine members.
iii. Creep of material at high temp.
iv. Excessive forced vibration, misalignments etc.
Thermal
Failure
i. Overheating of the
component.
ii. Lack of lubrication.
iii. Inadequate of cooling .
Chemical Failure
iv. Electrical insulation
i. failure.
Highly corrosive fluids containing
abrasive particles.
Classification maintenance problem based on
time span:
Short run production problem
Maintenance problem which are carried out in a sort
period of time are known as short run production system.
It may be hourly, daily
weekly and monthly.
Example:-
Hourly- inspection of correct lubricant, level of coolant,
sharpness of cutting tool.
Daily- cleaning of m/c, tightening of nuts, correct
cooling, inspection of various indicators, minor
adjustment of parts.
Weekly- Major adjustment, lubrication, tightening of
parts.
Monthly- checking for insulation, corrosion, safety
guards, checking of worn-out and distorted parts.
Procedure of Preventive maintenance :
1 . Job identification by preparing of facility
engineer
The very first step of PMP is to prepare the facility
register which defines that what to be maintained.

2 . Preparation of maintenance schedule

i. In this step we prepare a maintenance schedule. It is
simply a comprehensive list of all the incident
and their time of incidence.
ii. It gives the useful information regarding the method,
time and place of maintenance work, besides it also
provides secondary information about
maintenance man power requirement etc.
iii. It gives the various details regarding maintenance
like what, when, how, where.
3 . Preparation of history card
It not only gives the useful information about the result of
maintenance events but also furnishes the essential
details regarding the uses of machines, free of failures
and failure modes.
4 . Preparation of Job specification
i. In this step the job specification is prepared. It is simply
a document which provide the essential information
regarding the maintenance work to be done.
ii. In general practice these job details are specifications
compiled from maintenance schedules.
iii. They are a means of communicating the engineer’s
requirement to guide the workers.
iv. They are prepared separately for each job.
5 . Preparation of maintenance Programming
i. It is a sequential list which allocates specific
maintenance work to a specific period.
ii. In order to apply the job specification, the
maintenance programme is generally prepared for
long run when the machines/ equipment are to be
inspected.
iii. It is not a good practice because an industry can not
prepare a long run production well in advance since
too many factors arise and they will result into
change in production and maintenance
requirement.
iv. It presents a overall picture of present and future
maintenance commitments.
6. Preparation of weekly/Monthly maintenance
programmes
The next step under plant maintenance procedure is to
prepare the weekly/ Monthly maintenance programmes.
The maintenance programmes include the following
topics.
i. Reconditioning or replacing the lubricating oil
ii. Repairing and replacing worn out parts and tools etc
iii. Checking all the electrical connections of the
system
iv. Checking the control system
v. Checking the performance of each parts.
vi. Cleaning the interior parts like spark plugs, filters
radiators, crankcase, cylinders etc.
vii. It will lie under the long run maintenance
7. Preparing of inspection report
This step is followed after the maintenance program is over.
This is simply a document which furnishes the useful
information about the maintenance inspections which
were performed in the past.

8. Preparing of maintenance request

The next step under plant maintenance procedure is to

preparation of maintenance request. It is simply a
document or various maintenance suggestions and
recommendation given by the inspection report.
Suggestions are the useful feedback information that
comes from users end workers.
9. Feedback mechanism
In the last step the application of corrective and control
actions are available on the basis of feedback mechanism.
These corrective actions should be applied to respective
plant facilities at the initial stage of maintenance planning
or design.
Schedules of preventive maintenance:
It is simply a comprehensive list of all the incident and their
time of incident. It gives the following useful information
regarding the maintenance work.
i. What is to be done or maintained?
ii. How is to be maintained?
iii. When is to be maintained?
Besides this it may also provide the secondary information
regarding the place of maintenance and maintenance
requirement.
Maintenance Strategy :
i. A maintenance strategy defines the rules for the
sequence of planned maintenance work. It contains
general scheduling information, and can therefore be
assigned to as many maintenance task lists (PM task
lists) and maintenance plans as required. A
maintenance strategy contains maintenance packages
in which the following information is defined:
ii. The cycle in which the individual work should be
performed (for example, every two months, every
3,106.86 miles, every 500 operating hours)
iii. Other data which affects scheduling
Structure:
A maintenance strategy consists of:
Strategy header: Name of the strategy,
Scheduling parameters : Contain the scheduling data for
the respective maintenance strategy, which influence the
scheduling of maintenance plans.
Scheduling indicators
Maintenance packages
Scheduling Indicators :
Within a maintenance strategy, you can use
different scheduling indicators to specify the type of
scheduling you require or to define a cycle set :
i. Time-based (for example, every 30 days)
ii. Time-based by key date (for example, every 30 days
on the 30th day of the month)
iii. Time-based by factory calendar (for example,
every 30 working days)
iv. Performance-based (for example, every 50
operating hours)
Maintenance Packages :
Maintenance activities that must be performed at a
particular date or point in time are combined into
maintenance packages
Total Productive Maintenance (TPM)
i. Total productive maintenance (TPM) originated in
Japan in 1971 as a method for improved machine
availability through better utilization of maintenance
and production resources
ii. It can be considered as the medical science of
machines.
iii. Total Productive Maintenance (TPM) is a
maintenance program which involves a newly
defined concept for maintaining plants and
equipment.
iv. The goal of the TPM program is to markedly
increase production while, at the same time,
increasing employee morale and job satisfaction.
v. TPM brings maintenance into focus as a
necessary and vitally important part of the
business.
vi. It is no longer regarded as a non-profit
activity.
vii. Down time for maintenance is scheduled as
a part of the manufacturing day and, in
some cases, as an integral part of the
manufacturing process.
viii. The goal is to hold emergency and unscheduled
maintenance to a minimum..
Why TPM :
i. TPM was introduced to achieve the following
objectives.
ii. The important ones are listed below.
iii. Avoid wastage in a quickly changing economic
environment.
iv. Producing goods without reducing product quality.
v. Reduce cost.
vi. Produce a low batch quantity at the earliest possible
time.
vii. Goods send to the customers must be non defective.
Conclusion:
i. Today, with competition in industry at an all
time high, TPM may be the only thing that
stands between success and total failure for
some companies.
ii. It has been proven to be a program that works. It
can be adapted to work not only in industrial
plants, but in construction, building maintenance,
transportation, and in a variety of other situations.
iii. If everyone involved in a TPM program does his
or her part, an unusually high rate of return
compared to resources invested may be expected.
 ANY
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