Maintenance Functions-PQRM-RAM-Maintainability-Availability

1. MAINTENANCE ENGINEERING
MODULE I
Prepared By
Dhanesh S
Assistant Professor
Department of Mechanical Engineering
Ahalia School of Engineering and Technology

2. Why Maintenance?
■ Reduce business risks
■ Requires-high level of availability, reliability, assets
■ Maintenance Excellence-to assure reliability, maximum asset useful life and best
life cycle asset cost
■ Effects- business effectiveness and risk-safety, environmental integrity, energy
efficiency, product quality , customer service etc.

3. What is Maintenance?
■ Routine and recurring process of keeping a particular machine or asset in
its normal operating conditions so that it can deliver its expected
performance or service without causing any loss of time on account of
accidental damage or breakdown
or
■ Work that is required to be done to keep equipment in a running condition
such that it can be utilised to its full designed capacity and efficiency for
maximum amount of time

4. Maintenance Functions
■ Two categories-Basic Functions(job-wise) and Composite Functions
 Basic Functions:
 Replace
 Repair
 Overhaul
 Rebuild
 Service/Lubricate
 Inspect/Check

5. Maintenance Functions Ctd.
 Test
 Adjust
 Align
 Calibrate
 Measure
 Winding
 Install

6. Maintenance Functions Ctd.
 Composite Functions
 Protecting the buildings, structures and plants/factories
 Reducing downtimes and increasing equipment availability , also
helping in increasing equipment uitlization
 Analyze repetitive failure and arrange their elimination
 Forecast maintenance spares, tools and consumbaales and help their
procurement and inventory management
 Controlling and directing labour forces
 Economy is maintenance department
 Maximising utilization of available resources
 Cost reduction and cost control

7. Maintenance Functions Ctd.
 Preparing maintenance functions
 Waste reduction and waste recovery
 Improving technical communication
 Training of maintenance personnel on related jobs
Can also be classified into primary and secondary fucntions
■ Primary Functions:
 Select right bearing, fasteners, chains, belts, gears etc.
 Equipment inspection and lubrication
 Monitor oils, lubricants and lubrication systems etc
 Electrical control system

8. Maintenance Functions Ctd.
 Install and monitor proper ventilation and environmental control
systems to maximize service
 Utility generation and distribution
 Alterations, up-gradation and new installations
 Step-by-step troubleshooting and procedures for all components of
establishment.
 Secondary Function:
 Store keeping and inventory management
 Plant Protection
 Waste disposal
 Salvaging and recycling
 Plant and equipment insurance administration etc.

9. Maintenance-Objectives
■ To maintain plants and equipment at its maximum operating efficiency,
reducing downtimes and ensuring operational safety
■ To safeguard investments by minimizing rate of deterioration and
achieving this at optimum cost through budgeting and controls
■ To help management in taking decisions on replacements or new
investments and actively participate in specification preparation,
equipment selection etc
■ Help in implementation of suitable procedures for procurement, storage
and consumption of spares, tools and consumables etc
■ Standardization of spares and consumables
■ Running of centralized services like steam generation and distribution,
water supply, air suppy etc

10. Maintenance-Responsibilities
■ Proper care, up-keep and maintenance of equipments to achieve desired
availability
■ Ensure maintainability of old and new installations
■ Identify and correct chronic and costly equipment problems
■ Design, implement and monitor and effective and economically justified
preventive, predictive and or condition based maintenance programme
■ Comprehensive lubrication programme, monitor centralized oil,
lubrication, hydraulic, pneumatic and other circulatory systems
■ Monitor various on-site and off-site condition monitoring and built-in test
equipments
■ Protection against environment
■ Proper documentation and reporting of maintenance data and systematic
analysis of data and feedback

11. Maintenance-Responsibilities Ctd.
■ Coordinate with operation for safe operation practices
■ Help and coordinate project engineering for development and
implementing new projects, additions, modifications, replacements and
augmentations etc.
■ Review major purchases to assure correct specification and design
■ Failure analysis
■ Budgeting maintenance costs and periodically monitoring and control

12. Maintenance Responsibilities-Ctd
■ All maintenance function and responsibility can be grouped as
 MRO(Maintenance, repair , overhaul)
 Monitoring-various condition monitoring gadgets or systems
 Operation –operating repair machine shop etc
 Engineering-failure analysis, reliability and maintainability issue etc
 Procurement-preparing specificaiton and helping procurement
 Loss elimination-develop, implement and monitor a viable process to
continuously eliminate losses and waste

13. Maintenance-Benefits
■ Lower production unit cost
■ Reduced maintenance cost and reduced lifecycle cost
■ Better process stability
■ Extended equipment life and lesser asset replacement
■ Reduced maintenance part inventory
■ Reduced overtime and reduced out-sourcing
■ Improved employee safety and improved housekeeping
■ Reduced risk of environmental issues
■ Improved sense of employee pride/ownership
■ Reduced non-conformance reports and warranty claims and reduced
lapses in statutory obligations etc.