Chapter four

Maintenance Engineering
 Introduction, What is Maintenance?
What is Maintenance? The combination of all technical,
associated administrative and managerial actions during
the life cycle of an item in order to intended to retain or
restore an item into a state in which it can perform its
required function. This required function might be
defined as stated condition which it can perform its
designated function.
It is an important factor in product and service quality
and can be used as a strategy for successful competition.
Maintenance can be considered as a system with a set
of processes and activities carried out in parallel with
production or service systems.
 Introduction

The dictionary defines maintenance as “the work of

keeping something in proper condition, upkeep.”
This would imply that maintenance should be actions
taken to prevent a device or component from failing
or to repair normal equipment degradation
experienced with the operation of the device to keep
it in proper working order.
 IMPORTANCE OF MAINTENANCE
Keep Product and service quality: Poorly maintained
equipment's produce low quality products.
Guard Equipment's from frequent break downs and
as to provide adequate service to customers.
Employee or customer safety: Worn-out equipment is
likely to fail at any moment and these failures can
cause injuries to the workers, working on those
equipment's. Products such as two wheelers and
automobiles,
So if not serviced periodically, can break down
suddenly and cause injuries to the stress.
IMPORTANCE OF MAINTENANCE cont…
Customer satisfaction: When production equipment's
break down, products often can not be produced
according to the master production schedules, due to
work stoppages.

This will lead to delayed deliveries of products to the

customers are be come unsatisfied.
 Functions of Maintenance Engineering
Minimizing the loss of productive time because of
equipment failure (i.e. minimizing idle time of
equipment due to break down).
Minimizing the repair time and repair cost.
Minimizing the loss due to production stoppages.
Efficient use of maintenance personnel and
equipment's.
Prolonging the life of capital assets by minimizing
the rate of wear and tear.
To keep all productive assets in good working
conditions.
 Functions of Maintenance Engineering
To maximize efficiency and economy in production
through optimum use of facilities.
To minimize accidents through regular inspection
and repair of safety devices.
To minimize the total maintenance cost which
includes the cost of repair, cost of preventive
maintenance and inventory carrying costs, due to
spare parts inventory.
To improve the quality of products and to improve
productivity.
TYPES OF MAINTENANCE SYSTEM
Planned:- (Work organized and carried with fore thought,
control and record)
Unplanned:- (Emergency maintenance work caused by
unforeseen damage and accidents)
Preventive maintenance:- (Work intended to preserve an
asset, to prevent failure and to delete incipient faults)
Corrective maintenance:- (Work intended to restore an asset,
to the acceptable standard)
Running maintenance:- (Asset is in operation)
Shutdown maintenance:- (Asset is out of service)
Breakdown maintenance:- (Work implemented after failure but
based on advance planning)
Scheduled Maintenance; Reliability-based Maintenance Repair
Replacement, Overhaul Conditioned-based Maintenance
TYPES OF MAINTENANCE SYSTEM….
BREAKDOWNMAINTENANCE(BM)
Breakdown maintenance is maintenance performed on
equipment that has broken down and is unusable.
It is based on a breakdown maintenance trigger. It may be
either planned or it can be unplanned.
LIMITATION OF BM :Unpredictability which result in
either labor or materials being unavailable; therefore delay in
time taken for a repair,
Increasing equipment downtime can result in unnecessarily
expensive charges that may have been avoided can also
affect budgets.
TYPES OF MAINTENANCE SYSTEM….
PLANNED MAINTENANCE (PM)
The planned maintenance is an organized type of maintenance,
which takes care of other aspects such as control and records
required for this type of work.
Method :First of all, a work study has to be carried out to
decide the periodicity/ frequency of the maintenance work.
Time study can also suggest the ways and means of devising
optimal maintenance schedules for the given system.
Features :The work is planned beforehand to avoid random
failures.
It decides ‘Who’ will carryout 'what‘ maintenance work, by
'when'. Specific instructions for each type of equipment have
to be provided in greater detail .The type of maintenance job
will depend upon the nature of equipment and its working
conditions.
 TYPES OF MAINTENANCE SYSTEM….
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
equipment/facilities 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.
TYPES OF MAINTENANCE SYSTEM….
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.
The most important principle to keep continuous
management support is: “If it is not going to save money,
then don’t do it!”
There are seven elements of PM
a. Inspection: Periodically inspecting materials/items to
determine their serviceability by comparing their
physical, electrical, mechanical, etc., characteristics (as
applicable) to expected standards
TYPES OF MAINTENANCE SYSTEM….
b. Servicing: Cleaning, lubricating, charging, preservation,
etc., of items/ materials periodically to prevent the
occurrence of incipient failures
c. 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.
TYPES OF MAINTENANCE SYSTEM….
d. Testing: Periodically testing or checking out to
determine serviceability and detect electrical/mechanical-
related degradation
e. Alignment: Making changes to an item’s specified
variable elements for the purpose of achieving optimum
performance
f. Adjustment: Periodically adjusting specified variable
elements of material for the purpose of achieving the
optimum system performance
g. Installation: Periodic replacement of limited-life items
or the items experiencing time cycle or wear
degradation, to maintain the specified system tolerance.
TYPES OF MAINTENANCE SYSTEM….
TYPES OF MAINTENANCE SYSTEM….
Some characteristics of a plant in need of a good
preventive maintenance program are as follows:
 Low equipment use due to failures
 Large volume of scrap and rejects due to unreliable
equipment
 Rise in equipment repair costs due to negligence in
areas such as regular
 lubrication, inspection, and replacement of worn
items/components
 High idle operator times due to equipment failures
 Reduction in capital equipment expected productive
life due to unsatisfactory maintenance
TYPES OF MAINTENANCE SYSTEM….
There are a number of steps involved in developing a
PM program.
presents six steps for establishing a highly effective PM
program in a short period. Each step is discussed
below:-
1. Identify and choose the areas:- Identify and
selection of one or two important areas to
concentrate the initial PM effort.
These areas should be crucial to the success of overall
plant operations and may be experiencing a high degree
of maintenance actions. The main objective of this step
is to obtain immediate results in highly visible areas, as
well as to win concerned management support.
TYPES OF MAINTENANCE SYSTEM….
2. Identify the PM needs:- Define the PM requirements.
Then, establish a schedule of two types of tasks: Daily
PM inspections and periodic PM assignments. The daily
PM inspections could be conducted by either
maintenance or production personnel.
An example of a daily PM inspection is to check the
waste water settleable solids concentration.
Periodic PM assignments usually are performed by the
maintenance workers.
Examples of such assignments are replacing throwaway
filters, replacing drive belts, and cleaning steam traps
and permanent filters.
TYPES OF MAINTENANCE SYSTEM….
3. Establish assignment frequency:- Establish the
frequency of the assignments. This involves
reviewing the equipment condition and records.
Normally, the basis for establishing the frequency is
the experience of those familiar with the equipment
and the recommendations of vendors and
engineering.
It must be remembered that vendor
recommendations are generally based on the typical
usage of items under consideration.
TYPES OF MAINTENANCE SYSTEM….
TYPES OF MAINTENANCE SYSTEM….
4.Prepare the PM assignments:- Daily and periodic
assignments are identified and described in detail, then
submitted for approval.
5.Schedule the PM assignments on annual basis:-The defined
PM assignments are scheduled on the basis of a twelve-month
period.
6. Expand the PM program as necessary:- After the
implementation of all PM daily inspections and periodic
assignments in the initially selected areas, the PM can be
expanded to other areas.
TYPES OF MAINTENANCE SYSTEM….
PM MEASURES
Three important measures of PM are:
mean preventive maintenance time (MPMT),
median preventive maintenance time (MDPMT), and
maximum preventive maintenance time (MXPMT).
Each measure is described below.
MEAN PREVENTIVE MAINTENANCE TIME (MPMT)
MPMT is the average item/equipment downtime needed
to conduct scheduled PM. This time does not include
PM time expended on the equipment/item during
operation or administrative and logistic downtime.
Mean time for PM is defined by
TYPES OF MAINTENANCE SYSTEM….

where
M = total number of data points,
MPMTi=mean or average time needed to perform ith preventive
maintenance action, for i=1, 2, 3,…,m,
fi=frequency of ith preventive maintenance action in actions per
operating hour after adjustment for equipment duty cycle.

MEDIAN PREVENTIVE MAINTENANCE TIME (MDPMT)

This is the item/equipment downtime needed to carry out
50% of all scheduled preventive maintenance actions on
the item/equipment under the conditions outlined for
MDPMT. For lognormal distributed PM times, the
MDPMT is given by
TYPES OF MAINTENANCE SYSTEM….
Where: λi = constant failure rate of
element I of the item/equipment for
which maintainability is to be
evaluated, adjusted for factors such as
duty cycle, tolerance and interaction
failures, and catastrophic failures that
will lead to deterioration of item/
equipment performance to the degree
that a maintenance action will be
started, for i=1, 2, 3,…,m.
MAXIMUM PREVENTIVE MAINTENANCE TIME (MXPMT)

This is the maximum item/equipment downtime required to accomplish a

given percentage of all scheduled preventive maintenance actions on
the item/equipment under consideration. For lognormal distributed PM
times, the MXPMT is given by
TYPES OF MAINTENANCE SYSTEM….

Where y = value from table of normal distribution

corresponding to the given percentage value at which
MXPMT is defined (e.g.,
Y = 1.283 for the 90th percentile and
Y = 1.645 for the 95th percentile). log MPMT is the M

mean of logarithms of MPMT and is expressed by i

 λ logMPMT
i1
i i
logMPMTm  m

λ
i1
i

1/2
 m  m  



 logMPMT  i
2
 
 logMPMTi    m 
 
S logMPMT  
i1  i1  

 m 1 
 

 

TYPES OF MAINTENANCE SYSTEM….

PM MODELS
INSPECTION OPTIMIZATION MODEL I
Inspections are often disruptive, but they usually reduce downtime
because of lesser number of failures. This model can be used to
obtain the optimum number of inspections per facility per unit of
time. Total facility downtime is defined by:- equ 1
TYPES OF MAINTENANCE SYSTEM….

By differentiating the above Eq, 1 with respect to y, we get

equ 2

By setting above Eq. equal to zero and then rearranging, we obtain

Eq 3

where
y= optimum number of inspections per facility per unit of time.
By substituting Eq. (3) into Eq. (1) yields then we gate eq 4

where
TDT = total optimal downtime per unit of time for a facility.
TYPES OF MAINTENANCE SYSTEM….

Example 4.1
An engineering facility was observed over a period of time and
we obtained the following data:
Tb = 0.1 month, Ti = 0.05 month, c = 3
Using Eq. (3), calculate the optimal number of inspections
per month.
Using the given values in Eq. (3), we get
TYPES OF MAINTENANCE SYSTEM….

INSPECTION OPTIMIZATION MODEL II

This is similar to Inspection Frequency Model I. It can be used to
determine optimum inspection frequency in order to minimize the
per-unit-of-time equipment/facility downtime.

In this model facility/equipment (per-unit time) total downtime is

the function of inspection frequency. Mathematically, it is
defined as follows: equ 5
TYPES OF MAINTENANCE SYSTEM….

Where

• TDT(n) = facility/equipment total downtime per unit of time,

• DTi = equipment/facility downtime due to per-unit-of-time
inspection,
• DTr = equipment/facility downtime due to per-unit-of-time
repairs,
• n = inspection frequency,
• λ (n) = equipment/facility failure rate,
• μ = equipment/facility repair rate,
• 1/θ = mean of exponentially distributed inspection times.
TYPES OF MAINTENANCE SYSTEM….

By differentiating Eq. (5) with respect to n, we get equ 6

Setting Eq. (6) equal to zero and rearranging yields equ 7

The value of n will be optimum when the left and right sides of Eq.
(7) are equal. At this point the equipment/facility total downtime
will be minimal
Example 4.2
Assume the failure rate of a system is defined by eq 8

where f is the system failure rate at n = 0. Obtain an expression for

the optimal value of n by using Eq. 7
By substituting Eq. (8) into Eq. (7), we get eq 9
TYPES OF MAINTENANCE SYSTEM….

Rearranging Eq. (9) yields then equ 10

where
= = optimal inspection frequency .
Example 4.3
Assume that in Example 4.3 we have the following:

Calculate the optimal value of the inspection frequency, n.

Inserting the given values into Eq. (10) yields

This means that roughly one inspection per month will be optimal.
TYPES OF MAINTENANCE SYSTEM….

PM ADVANTAGES AND DISADVANTAGES

The performance of PM has many advantages including
increase in equipment availability, performed as convenient,
balanced workload, reduction in overtime, increase in
production revenue, consistency in quality, reduction in need
for standby equipment, stimulation in preaction instead of
reaction, reduction in parts inventory, improved safety,
standardized procedures, times, and costs, scheduled
resources on hand, and useful in promoting benefit/cost
optimization.
Some disadvantages of PM are: exposing equipment to
possible damage, using a greater number of parts, increases
in initial costs, failures in new parts/components, and
demands more frequent access to equipment/item
TYPES OF MAINTENANCE SYSTEM….

Corrective Maintenance
Corrective maintenance is an unscheduled maintenance
action, basically composed of unpredictable maintenance
needs that cannot be preplanned or programmed on the
basis of occurrence at a particular time.

The action requires urgent attention that must be added,

integrated with, or substituted for previously scheduled
work items.
TYPES OF MAINTENANCE SYSTEM….

5.Servicing:Servicing may be needed because of the

corrective maintenance action, for example, engine repair can
lead to crankcase refill, welding on, etc. Another example
could be that the replacement of an air bottle.

Types of corrective maintenance.

TYPES OF MAINTENANCE SYSTEM….

CORRECTIVE MAINTENANCE TYPES

Corrective maintenance may be classified into five major
categories as shown in Fig. above
These are: fail-repair, salvage, rebuild, overhaul, and
servicing. These categories are described below.
1.Fail-repair: The failed item is restored to its operational
state.
2.Salvage:This element of corrective maintenance is
concerned with disposal of non repairable material and
use of salvaged material from non repairable
equipment/item in the repair, overhaul, or rebuild
programs.
TYPES OF MAINTENANCE SYSTEM….

3.Rebuild:This is concerned with restoring an item to a

standard as close as possible to original state in
performance, life expectancy, and appearance.
4.Overhaul: Restoring an item to its total serviceable
state as per maintenance serviceability standards, using
the “inspect and repair only as appropriate” approach.
may require system recharging.
5.Servicing:Servicing may be needed because of the
corrective maintenance action, for example, engine repair can
lead to crankcase refill, welding on, etc. Another example
could be that the replacement of an air bottle.
TYPES OF MAINTENANCE SYSTEM….

For our purpose, we assume that corrective maintenance is

composed of five major sequential steps,
These steps are: fault recognition, localization, diagnosis,
repair, and checkout.
The active repair time is made up of the following
subcomponents:
 Preparation time
 Fault location time
 Spare item obtainment time
 Fault correction time
 Adjustment and calibration time
 Checkout time
TYPES OF MAINTENANCE SYSTEM….
Autonomous Maintenance

Autonomous Maintenance (“Jishu Hozen” in Japanese) is

to keep and maintain the equipment through a team work
i.e.
through joint responsibilities of production operators and
maintenance staff instead of old conventional style in
which machine maintenance is considered to be the sole
responsibility of the maintenance department.
Autonomous maintenance challenges the, old culture and
conventional mindset approach like
Autonomous Maintenance cont…
Produce (as Production Operator Works on Machine to
Produce Parts) and Maintain & Fix (it as Maintenance
Operator Maintain & Fix It).
Autonomous Maintenance focus on changing the mind-set
and it is the new way of thinking and working.
All are responsible for their machines and equipment
maintenance (Thus, it tries to develop an Ownership
Concept among all the stakeholders).

Production Staff are herein referred as “Parents” which

have the task to take care of all the basic requirements of
their child i.e. their own “Machine” in order to keep the
child healthy.
Autonomous Maintenance cont…

Goals of Autonomous Maintenance:

Following are the main Goals of the autonomous maintenance.
1. Prevent Equipment Deterioration Through Proper Operation
& Control
2. Like New Status Using Equipment Restoration & Proper
Management
3. Sustain Basic Conditions
4. Raise Skill Levels, Making Operator Equipment Competent
Equipment Deterioration:
The root cause of the major equipment failures is
deterioration. There are two types of equipment
deterioration.
1. Natural Equipment Deterioration
Autonomous Maintenance cont…

Natural Deterioration:
It is natural and normal phenomenon. It occurs as a result
of friction, wear and tear and equipment normal stresses
as per the defined life span of the machine.
Although machine operated in proper procedure
recommended, effective maintenance conducted to
maintain the basic conditions (Cleaning, Inspection &
Lubrications) and environmental conditions due to
continuous usage of machine.
Natural deterioration countermeasures include time based
quality maintenance and by improving the design of the
machines and its components for longer machine life.
Autonomous Maintenance cont…
Forced/ Accelerated Deterioration:
It is abnormal phenomenon. It occurs due to abnormal wear
and tear due to Mal Operation procedures, Bad/no Machine
Maintenance and harsh environmental conditions etc. Forced/
Accelerated deterioration countermeasures include
implementing and sustaining Jishu Hozen i.e. Autonomous
Maintenance.
Some of the examples of Forced/ Accelerated Deterioration
include;
1. Loose Nut & Bolts
2. Misalignments in Machine
3. Bad Wiring
4. Improper Cleaning Causing Dust and Dirt
5. Rusting
Autonomous Maintenance cont…

The Seven Steps of Autonomous Maintenance Steps:

Following are the seven steps of Autonomous Maintenance
Step 0: Preparation for Autonomous Maintenance
Step 1: Initial Cleaning (Dust & Dirt)
Step 2: Eliminating Sources of Contamination & Hard to
Access Areas
Step 3: Preparing Cleaning, Lubrication & Tightening
standard
Step 4: General Inspection
Step 5: Autonomous Inspection
Step 6: Standardization through Visual Management
Step 7: Implementing Autonomous Management
Computerized Maintenance Management System

The objective of maintenance organizations is to

maximize uptime in the most cost effective manner.
To accomplish this objective, the following strategies
must be clearly specified:
A Computerized maintenance management system
(CMMS) is basically information systems adapted to
serve maintenance.
CMMS aids in the process of data collection,
recording, storing, updating, processing,
communicating, and forecasting. It is essential for
planning, scheduling, and controlling the
maintenance activities.
Computerized Maintenance Management System cont…

Through effective reporting, a CMMS can provide

maintenance managers and engineers with the information
needed for sound decision making to control and improve the
maintenance process.
The success of a CMMS can be measured by its ability to
support the maintenance process.
CMMS usually includes the following functions:
 Equipment identification and bill of material
 Preventive maintenance
 Work order management
 Planning and scheduling
 Inventory control and purchasing
 Labor and job standard
 Equipment history
Computerized Maintenance Management System cont…

 Costs and budget

 Performance reports
 Quality reports

There area of five models which support the above function

those are listed. These are as follows
 Equipment management
 Work order control
 Crafts management
 Material supply and control
 Performance reports.
Computerized Maintenance Management System cont…

Equipment Management Module

This module tracks equipment lubrication and preventive
maintenance.
This module provides information about equipment
identification, location, installation date, status, technical
information, equipment history and preventive maintenance
schedule, special tools, and safety procedure. Additional
information can be stored about lubrication program
specifications, lubrication oil, and method of application,
standard jobs, and repair history.
It interacts with work order planning and controls in order to
generate the needed work orders.
Computerized Maintenance Management System cont…

Maintenance management information system structure

Computerized Maintenance Management System cont…

Work Order Control Module

The work order control module automates the process of
work order generation. This module is the heart of the
CMMS since it is responsible for the execution of the
work order system, which is the heart of the maintenance
control. The work order serves the following functions:
1. Documenting the process of work requests and
authorizing the work to be performed.
2. Planning, monitoring, and controlling the actual work.
3.Helping in data collection about maintenance
performance and costs.
4. Providing the needed information for feedback and
continuous improvements.
Computerized Maintenance Management System cont…

The work order requires two types of information.

The first type is used for planning and scheduling,
and the second is for identification.
The categories of information are listed below:
 Work order number
 Date
 Problem definition and tool needed
 Equipment number, work plan, and location
 Estimated man-hours and estimated costs
 Craft code
 Material
Computerized Maintenance Management System cont…

Crafts Management Module

This module keeps track of craft status in order to
provide the planner/scheduler the information needed
for scheduling work orders. The planner/scheduler,
when executing the work order control module, needs to
interface with this module to know manpower
availability.
Material Supply and Control Modules
Material requirement planning and inventory control are
critical for overall performance of the maintenance
system. A CMMS must provide an effective inventory
and material supply.
Computerized Maintenance Management System cont…

In the process of planning a work order, the planner

identifies the needed spares and material. Then, he
checks the availability of spares and material in the
needed amounts prior to opening the work order. The
availability of spare parts and material is critical and
essential for smooth planning, scheduling, and
controlling of maintenance work.
Performance Reporting Module
This module of CMMS interacts with all other modules to
monitor the maintenance activities and provides various
kinds of cost and performance reports.
The module can be customized to generate all needed
reports. However, the following reports are usually
provided.
Computerized Maintenance Management System cont…

1. Cost reports. The system provides details about the

maintenance costs. The costs can be prepared by
equipment or by cost center where the equipment is
located. The cost includes labor, spare parts, material,
and facility costs.
2. Completed work orders. This is a summary of work
orders completed in a specified time window.
3. Backlog report. This is a summary of work orders in
the maintenance backlog. The work orders can be
classified according to the cause of their backlog, which
could be spare parts, crafts, or other technical reasons.
4. Work order status report. This includes the progress
of all work orders.
Computerized Maintenance Management System cont…

5. Craft performance report. This report includes a

summary of craft productivity.
6. Distribution of maintenance work by priority.
7. Estimated versus actual hours report.
8. Plant availability report. This report provides
information about equipment availability.
9. Plant reliability report. This report provides
information on major equipment reliability and
mean time between failure and
10. Quality reports. This report provides information
about repeat and substandard jobs and training
records.
Computerized Maintenance Management System cont…

Maintenance Reporting
The CMMS facilitates the preparation of reports to
management. These reports aid management in
taking actions to improve the status of the
maintenance process.
The reports should be based on actual data and
should be presented in summarized and graphical
forms. Statistical indicators and trend analysis must
be an integral part of such reports. The following
general principal can be used for evaluating the
quality of reporting:
Computerized Maintenance Management System cont…

1. The report should be concise and based on actual

data. Standard cost figures and budgets should be used
to form basic benchmarks.
2. Some periodic reports should be reported in a
graphical form and must be compared with previous
periods to show trends.
3. Important information such as equipment downtime,
equipment losses, percentage of scheduled maintenance
work, backlog reports, and maintenance quality reports
should be available.
4. The CMMS should be able to provide most of these
reports.
Computerized Maintenance Management System cont…

5. These should be prepared in close coordination with

concerned departments, which should also provide
interpretation of the reports’ content.
6. Maintenance management should provide feedback on the
reports, and action must be taken to correct any mishaps.
Computerized Maintenance Management System cont…

Evaluation of Computerized Maintenance Management

Systems
The procedure in this section can be used for evaluating “off
the shelf” computerized management systems available in
the market or used as a guideline for developing an up-to-
date CMMS.
Evolution of CMMs for Effective Maintenance
The following characteristics need to be added to the
elements of CMMS.
1. Effective control over maintenance scheduling by
including heuristic scheduling rules, heuristic algorithms,
and mathematical programming techniques.
2. Modeling characteristics, such as simulation of the
maintenance systems.
Computerized Maintenance Management System cont…

3. Decision-making and forecasting capabilities.

The following modules of the CMMS need to be expanded
in order to incorporate the above 3 characteristics.
1. Equipment management.
2. Work order control.
3. Performance reporting.
Computerized Maintenance Management System cont…

Functions of computerized maintenance management systems

Computerized Maintenance Management System cont…

The chapter is not finished so…………….

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