Maintenance Is an important factor that affect productivity

1. MAIN10ANCE POLICY
(FOR EQUIPMENT SUBJECTED TO BREAKDOWN)
Submitted to-
Dr. Vijay Kumar Dwivedi
Associate Professor
Institute of Engineering and Technology
Department of Mechanical Engineering
Presented by-
Sameer Vishwakarma (178121004)
M.Tech.(Production)
III Semester
GLA University, Mathura

2. CONTENTS
• Introduction to Maintenance
• Introduction to Breakdown Maintenance
• Introduction to Breakdown Maintenance Policy for Equipment(s)
• Case Study
• Conclusion
• References

3. THINK ABOUT-
• Brushing teeth- Cost of Toothpaste and Brush
• Exercise- Where: Gym or Home?
• Taking shower- Cost and Quality of soap
• Applying make-up- When and how much?
• Taking rest or sleeping- How well?
And so many things that we do everyday or something we do episodically like
haircuts etc.
What can we call, all these activities?
THE MAINTENANCE…

4. Thus
‘ The activity or a work is done for proper functionality of an equipment
(brushing teeth) or a machine (sleeping) is called Maintenance.’
If Cost is introduced-
“Maintenance is a function to keep the equipment or machinery in their normal
operating condition by servicing or repairing or replacing some of the
components of a machine at minimum cost.”
Or
The technical meaning of maintenance involves functional checks,
servicing, repairing or replacing of necessary devices, equipment, machinery,
building infrastructure, and supporting utilities in industrial, business,
governmental, and residential installations at minimum cost.

5. EVOLUTION OF MAINTENANCE
•40’s- First
Generation
•60’s- Second
Generation
•80’s- Third
Generation
•2000 and onwards-
Fourth Generation

6. RELATIONSHIP BETWEEN MAINTENANCE AND
QUALITY
Resource- Ben Daya and Duffuaa 1995

7. DEPENDABILITY AND RAMS
Adapted from International Electrotechnical Commission(1990)

8. DEPENDABILITY AND RAMS
Dependability and RAMS according to EN 13306:2011 (CEN 2010)

9. PERFORMABILITY AND DEPENDABILITY
Adapted from International Journal of Performability Engineering (IJPE)

10. MAJOR STEPS IN MAINTENANCE

11. TYPES OF MAINTENANCE

12. BREAKDOWN MAINTENANCE
• 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/replacement.
• The maintenance staff locate any mechanical, electrical or any other fault to
correct it immediately.

13. TYPES OF BREAKDOWN MAINTENANCE
Breakdown maintenance can be subdivided into three parts-
1. Remedial Maintenance: Maintenance activities performed to
eliminate the source of failure without interrupting the continuity of
production process.
2. Deferred Maintenance: Maintenance activities are not immediately
initiated after occurrence of failure but are delayed without stopping
the production process.
3. Shutdown Maintenance: The production or production line is
completely stopped.

14. BREAKDOWN MAINTENANCE POLICY
• What is Policy?
A course or principle of action adopted or proposed by an organization or individual
• Synonyms of Policy
Plans, strategy, blueprint, approach, scheme, stratagem, programme, schedul, code, s
ystem, guidelines, intentions, notions, theory, line, position, stance,
attitude.
• Others-practice, custom, procedure, wont, way, tack, routine, matter of
course, style, pattern, convention, mode, rule

15. The Theories suggest following two policies foe equipment subjected to breakdown-
1. Repair Policy
2. Replacement Policy
a) Individual Replacement Policy
b) Group Replacement Policy
line-
“If Cost of repair or repeated repair is higher that cost of equipment, replace it.”
BREAKDOWN MAINTENANCE POLICY CONTD…

16. HOW TO CHOOSE BETWEEN REPAIR AND REPLACEMENT
POLICY?
1. Data-Driven Decisions
2. Analyze the Costs
3. Consider the Age of Equipment (near or beyond its expected life)
4. Consider the Cost of Repairs
5. Consider Downtime
6. Consider Safety
7. Consider Efficiency and performance
8. Capability
9. The existing equipment is technologically obsolete, spare parts are
expensive or hard to get, and skill requirements to properly repair and
maintain are hard to find.
10. The existing equipment poses an unacceptable security risk, health and safety
risk, or environmental risk and the cost to mitigate the risk exceeds the asset life
cycle replacement cost.
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17. Steps involved in BMP-
1. Prioritize your maintenance tasks- Low, Medium and High
2. Analyze historical work orders
3. Prioritize equipment based on whether delays in fixing them are acceptable.
4. Use historical data to identify equipment that breaks down frequently
5. Use historical data to find the most common equipment failures
6. Improve spare parts availability
7. Review manufacturer recommendations regularly
Source: FastMaint ™ CMMS Software guideline
BREAKDOWN MAINTENANCE POLICY CONTD...

18. One other software company SAP suggest following model-
BREAKDOWN MAINTENANCE POLICY CONTD…

19. CASE-STUDY

21. REFERENCES
• Christer Stensrom and Aditya Phadia, Lulea University of Technology, Sept, 2013.
• Asset Maintenance Policy, university of Queensland
• Guidelines by SM Global’s CMMS (Corrective Maintenance Management System)
• https://www.micromain.com/asset-repair-or-replace
• Sharma S.D (2004), “Operations Research”, Kedarnath Ramnath & Co Publishers
• Optimal maintenance policy for a system with preventive repair and two types of failures,
Zheng et al.,(2016)
• Numerical study of inventory management under various maintenance policies; Joeri
Poppe et al.,(2017)
• https://artoftroubleshooting.com/2014/04/25/the-50-percent-rule-repair-or-replace-revisited/