This report is the seminar study of different maintenance strategy for improvement of productivity at industry.

1. SEMINAR ON
MAINTENANCE STRATEGIES FOR
IMPROVEMENT OF
PRODUCTIVITY AT INDUSTRY
By
GREEJESH PRAKASH

2. Key Phrases
■ Maintenance, Maintenance Strategy, Types of Maintenance, Maintenance System,
Productivity, Maintenance Engineering, Maintenance Cost

3. Objectives
■ To highlight the benefits of maintenance strategy
■ To study the new strategy of maintenance for better productivity
■ Approaches for the better maintenance strategy leading in to better profitability

4. What is Maintenance Strategy?
“Management method used in order to achieve the maintenance
objectives.”

5. Maintenance Objectives?
■ The targets assigned to or accepted by the management and maintenance
department.
■ Targets may include availability, cost reduction, product quality, environment
preservation, safety

6. Introduction
■ Maintenance is an activity carried out for any equipment to ensure its reliability to
perform its functions
■ It is 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, or to restore to its favorable operating condition

7. Another Perspective
■ Maintenance function is not only to maintain
■ Its also to enhance the process or the plant operation system
■ With the turnaround planning.
■ Most management now saw maintenance efficiency as
■ A factor that can affect the all business effectiveness and risk-safety,
■ Environmental integrity
■ Energy efficiency
■ Product quality and customer service and not contained only to plant availability and
cost.

8. Another Perspective
Maintenance
Environmental
integrity
Energy
efficiency
Product quality
customer
service
Plant
Availability
and
Cost

9. Methodologies
Direct
Participation
Technical
Experience
Primary
Sources
Internet
Studies
Books
Interviews
Secondary
Sources

10. Literature Review
FIRST GENERATION SECOND GENERATION THIRD GENERATION
 Fix it when it broke  Scheduled overhauls
 Systems for planning and
controlling work
 Low-tech computerization
 Condition monitoring
 Design for reliability and
maintainability
 Hazard studies
 High-tech computers
 Failure Modes & effect
analysis
 Expert Systems
 Multi-tasking and team
work
1930 1940 1950 1960 1970 1980 1990 2000 NOW

11. Literature Review
Fourth
Generation of
Maintenance
Definite
negotiation of risk
Coherence between
functional demand,
equipment design
and maintenance
Development in
information
technology to
detect, predict,
diagnose and
prevent

12. Literature Review
Fourth
Generation

13. Different Strategies
Maintenance Strategy Maintenance Approach Signification
Breakdown Maintenance Fix-it when broke Large maintenance budget
Preventive Maintenance
Scheduled Maintenance
Periodic component
replacement
Predictive Maintenance Condition-based Monitoring
Maintenance decision based on
equipment condition
Proactive Maintenance Detection of Sources of Failures Monitoring and correcting failing
root causes

14. Different Strategies
■ Reliability Centered maintenance
■ Root Cause Failure Analysis

15. Discussion
■ In the maintenance enterprise state, presentation assurances and constant
upgrading goals deliver better switch over maintenance outcomes
■ Guarantee manufacture goals which are actuality stretched
■ The assortment of a precise equipment of low installed budget helps to decrease
budget
■ Driving up maintenance budget and downtime which is not promising to the vender
maintenance team
■ Therefore an enhanced solution should be a combined and aligned method

16. Finding
■ Maintenance should be initiated when the facility or system is just a proposal, which
is even earlier the preparation stage
■ And lasts up until it is time to for the facility to de-commissioning

17. Finding
Proposal Construction Commissioning
Operation Decommissioning
Integrated and aligned approach of maintenance program

18. Findings
■ By dropping the direct and indirect cost of system failure, the perception of
productive, effective and cost-effective can be attained
■ Return of Assets = Revenue -------------------------------- (1)
(Asset Value)
■ Revenue = Price x Volume -------------------------------- (2)
■ Volume = Max. Capacity x Overall Equipment Effectiveness ------------- (3)
Effective maintenance has a constructive result on calculation (1), (2) and (3).
Enhanced maintenance assistances to improve efficiency by dropping the need for
costly capital advancements to upturn output.

19. Effective Maintenance Vs Non Effective Maintenance

20. Conclusion
■ fix-it-when-it-broke to a more complex approach
■ adopted maintenance strategy of a more integrated approach and alignment
■ maintenance will also be part of the investment decision-making
Improved
Maintenance
Effectiveness
Productivity
Profitability

21. Recommendation
■ Any industry should use effective strategy in order to improve efficiency
■ Reducing the direct and indirect cost of maintenance using preventive and
predictive maintenance will remarkably reduce the maintenance cost
■ Maintenance actions could be started when the facility or system is just a proposal.
Proposal Construction Commissioning Operation
Decommissioning

22. References
■ HISHAM BIN JABAR, Segi Perkasa Sdn Bhd, PLANT MAINTENANCE STRATEGY: KEY
FOR ENHANCING PROFITABILITY
■ General Electric (www.ge.com)
■ Dhillon, S. B. (2006). (2006) Maintainability, Maintenance, and Reliability for
Engineers
■ Mobley, K. (2004). Maintenance Fundamentals (2nd edition). Elsevier Inc.
■ Moubray JM. (2000). Maintenance Management – A New Paradigm. Retrieved from
Maintenance Resources.Com