2. INTRODUCTION TO MAINTENANCE
What is Maintenance?
Its an activity carried
out for any equipment
to ensure its reliability
to perform its
functions.
How people think about it?
• Any activity carried out on
an asset in order to ensure
that the asset continues to
perform its intended
functions.
• To repair any equipment
that has failed
• To keep the equipment
running and restore to its
favorable operating
condition
3. PURPOSE OF MAINTENANCE
• Enable the maintenance function to provide
better service to production promotes better
equipment performance.
• Prevent breakdown or failures
• Minimize production loss from failures
• Increase reliability of the operating systems
4. CHALLENGES
• Need to model the different elements
(technical, commercial, operational)
• Need to understand the underlying
degradation processes.
• Adequate data to build and validate models
6. PROBLEMS IN MAINTENANCE
• Lack of management attention to
maintenance.
• Little participation by accounting in analyzing
and reporting costs.
• Difficulties in applying quantitative analysis.
• Difficulties in obtaining time and cost
estimates for maintenance works.
• Difficulties in measuring performance.
7. PROBLEMS EXIST DUE TO:
• Failure to develop written objectives and
policy
• Inadequate budgetary control
• Inadequate control procedures for work
order, service requests etc.
• Don’t follow standards
• Absence of cost reports to aid maintenance
planning and control system
8.
9. STRATEGIC MAINTENANCE
• Differentiating among types of equipment
with respect to the planned maintenance and
capacity requirement.
• It will help to understand of which equipment
is most critical to plant operations.
10. STRATEGIC MAINTENANCE
• The failure to set maintenance will lead to
equipment disruptive breakdowns.
• To avoid conflicts, operators will need training
in order to take on routine maintenance tasks.
13. CORRECTIVE/ BREAKDOWN
MAINTENANCE
ADVANTAGES:
Down times are non-critical
Repair costs are less than other type of maintenance
Financial justification for scheduling are not felt
DIS - ADVANTAGES:
Excessive delay in production & reduces output
Faster plant deterioration
Increases chances of accidents and less safety for both workers
and machines
More spoilt materials
Direct loss of profit
Can not be employed for equipments regulated by statutory
provisions e.g. cranes, lift and hoists etc
14. PREVENTIVE MAINTENANCE
ADVANTAGES:
locates weak spots of machinery and equipments
provides them periodic/scheduled inspections and minor
repairs to reduce the danger of unanticipated breakdowns.
Lower maintenance and repair costs
Less stand-by equipments and spare parts
Better product quality and fewer reworks and scraps
Increases plant life
DIS - ADVANTAGES:
Intensive, performance of unneeded maintenance etc.
15. PREDICTIVE MAINTENANCE
ADVANTAGES:
increased component life.
Preemptive corrective action
Reduced downtime
Reduced spares and
labor cost
improved worker moral etc
DIS - ADVANTAGES:
Increased investment in diagnostic equipments, staff training etc
16. RELIABILITY CENTERED
MAINTENANCE
ADVANTAGES:
most efficient maintenance program.
lower costs by eliminating unnecessary maintenance or overhauls
minimize frequency of overhauls
focused maintenance activities on critical equipments
reduced probability of sudden equipment failure
DIS - ADVANTAGES:
It can have significant startup cost, training, equipment etc.
17. WHY IS IMPROVING MAINTENANCE
PRODUCTIVITY SO CHALLENGING?
• Once an implementation plan is developed,
manufacturers must execute it in a way that
minimizes disruption to equipment operations
and maintenance staff.
• The nature of maintenance work makes it more
challenging to measure productivity and
effectiveness, to identify the root causes of
problems, and to make improvements.
• These overall challenges translate into specific
challenges in Strategy, Execution, and
Governance.
