Maintenance management widescreen


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Maintenance management widescreen

  1. 1. 1 Slides presented By: Sujeet Pandit 1
  2. 2. Contents Maintenance management Scope of Maintenance Objectives Impact of poor Maintenance Areas of Maintenance Maintenance Benefits Condition Based Maintenance Decisions (CBM) Types of Maintenance Breakdown Maintenance Preventive Maintenance Predictive Maintenance Routine Maintenance & Planned Maintenance Maintenance Decisions Maintenance Cost Maintenance Cost Numerical Total Productive Maintenance (TPM) Numerical 2
  3. 3. Maintenance Management 3
  4. 4.  The objective of maintenance is to maintain the capability of the system while controlling costs  Maintenance is all activities involved in keeping a system’s equipment in working order or operating condition  Maintenance is concerned with avoiding or minimizing downtime or to avoid undesirable results due to system failure. Maintenance Management 4
  5. 5. Scope of Maintenance A) Primary Function: a) Maintenance of existing plants & equipments. b) Maintenance of existing plant buildings and grounds. c) Equipment inspection and lubrication. d) Utility generation and distribution. e) Alterations to existing equipments and buildings. f) New installations of equipments and buildings. 5
  6. 6. Scope of Maintenance..contd… B) Secondary Function: a) Storekeeping (keeping stock of spares parts). b) Plant protection including fire protection. c) Waste disposal. d) Salvage. e) Insurance administration (against fire, theft, etc.). 6
  7. 7. Objectives • To increase functional reliability of production facilities. • To enable product or service quality to be achieved through correctly adjustment, serviced and operated equipment. • To maximize the useful life of the equipment. • To minimize the total production or operating cost directly attributed to equipment service & repair. • To minimize the frequency of interruptions to production by reducing breakdowns. • To maximize the production capacity from the given equipment resources. • To enhance the safety of manpower. 7
  8. 8. Impact of Poor Maintenance • Production capacity: • Production costs: • Product and service quality: • Employee or customer safety: • Customer satisfaction: 8
  9. 9. Areas of maintenance management • Civil Maintenance • Mechanical maintenance • Electrical Maintenance 9
  10. 10. Maintenance Benefits Maintenance Reduced inventory Lower Operating costs Faster, more Dependable throughput Improved capacity Continuous improvement Improved quality Higher productivity 10
  11. 11. Condition Based Maintenance Decisions (CBM) • To deduct the failures before they occurs. • To carry out maintenance only when required. • To reduce the maintenance costs and downtime costs. Methodology of CBM • Proper identification and location of machines/equipment by codification. • Selection of critical machines and systems. • Identifying components/elements. • Fixing conditions parameters. • Monitoring Techniques. • Trend monitoring. • Follow up. 11
  12. 12. Types of maintenance maintenance Planned maintenance Preventive maintenance Predictive maintenance Running maintenance Shutdown maintenance Breakdown maintenance Routine maintenance 12
  13. 13. Breakdown Maintenance  Involves performing maintenance activities after a machine breakdown or malfunction has occurred and then must be repaired on an emergency or priority basis.  Breakdown maintenance includes repairs, replacement of parts or even overhaul to ensure the machine is put back in operating condition. 13
  14. 14. Preventive Maintenance  Involves performing maintenance activities before the equipment fails.  Objectives are : i) To reduce frequency and severity of interruptions to production caused by machine malfunctions. ii) To detect potential problems earlier and avoid the associate cost. 14
  15. 15. Preventive Maintenance – cont.  Preventive Maintenance activities includes regular inspection, machine adjustments, lubrication, cleaning and parts replacement  Two type of preventive maintenance i) Routine maintenance ii) Inspection 15
  16. 16. Predictive maintenance • This is a method in which the service life of important part is predicted based on inspection or diagnosis, in order to use the parts to the limit of their service life. Compared to periodic maintenance, predictive maintenance is condition based maintenance. It manages trend values, by measuring and analyzing data about deterioration and employs a surveillance system, designed to monitor conditions through an on-line system. 16
  17. 17. Routine Maintenance & Planned Maintenance • Ongoing maintenance activities such as cleaning washrooms, grading roads hand mowing lawns, which are required because of continuing use of the facilities. Planned Maintenance • There is only one reason to support a planned maintenance program. Planned maintenance increases profits. The primary objective for any business is to produce profits for the owner. Profit oriented goals apply to an elderly couple operating a corner grocery store, as well as to large corporations. Even maintenance consulting firms have to operate at a profit. Maintenance control in a mine, fleet or plant can increase profits in two ways: Increased production: Reduction of wasteful or unnecessary downtime increases production, thereby increasing profits. Reduced costs: Higher productivity, method improvements or material changes can reduce maintenance costs, thereby increasing profits. 17
  18. 18.  How much preventive & breakdown maintenance  Who performs maintenance  Centralized, decentralized, operator etc.  Contract or in-house  When to replace or repair  How much to replace  Individual or group replacement  Spare parts inventory and standby machines. Maintenance Decisions 18
  19. 19. Maintenance Cost Cost associated with maintenance are: • Downtime (Idle time cost) cost due to equipment breakdown. • Cost of spares or other material used for repairs. • Cost of maintenance labour and overheads of maintenance departments. • Losses due to inefficient operations of machines. • Capital requirements required for replacement of machines. 19
  20. 20. Cost Amount of maintenance activity Cost of breakdown maintenance Maintenance Costs 20
  21. 21. Maintenance Cost Example Should the firm contract for maintenance on their printers? Number of Breakdowns Number of Months That Breakdowns Occurred 0 2 1 8 2 6 3 4 Total: 20 Average cost of breakdown = 300 Use service contract - cost 150 per month and average breakdown is 1 per month. 21
  22. 22. Maintenance Cost Example 1. Compute the expected number of breakdowns Number of Breakdowns Frequency Number of Breakdowns Frequency 0 2/20 = .1 2 6/20 = .3 1 8/20 = .4 3 4/20 = .2 ∑ Number of breakdowns Expected number of breakdowns Corresponding frequency= x = (0)(.1) + (1)(.4) + (2)(.3) + (3)(.2) = 1.6 breakdowns per month 22
  23. 23. Maintenance Cost Example 2. Compute the expected breakdown cost per month with no preventive maintenance Expected breakdown cost Expected number of breakdowns Cost per breakdown= x = (1.6)(300) = 480 per month 23
  24. 24. Maintenance Cost Example 3. Compute the cost of preventive maintenance Preventive maintenance cost Cost of expected breakdowns if service contract signed Cost of service contract = + = (1 breakdown/month)(300) + 150/month = 450 per month 24
  25. 25. Total Productive Maintenance (TPM)  Additional requirements of:  Designing machines that are reliable, easy to operate and easy to maintain.  Emphasizing total cost of ownership when purchasing machines, so that service and maintenance are included in the cost.  Developing preventive maintenance plans that utilize the best practices of operators, maintenance departments, and depot services.  Training workers to operate and maintain their own machines. 25
  26. 26. Maintenance Performance Evaluation 1. Total Plant maintenance Productivity (TPMP) Plant output in a given period TPMP = Total maintenance cost in a given period time Down Time Hours 2. Down Time Index = *100 Production Hours Maintenance Cost 3. Maintenance Cost Index = *100 Capital Cost Hours the equipment ran at capacity 4. Equipment Utilization = Hours the equipment was available to run at Capacity during evaluation period Total man power actually worked on the job 5. Man Power Efficiency = Total man hours scheduled for these work 26
  27. 27. Numerical Q. PQR company has kept records of breakdowns of it’s machines for a 300 days work year as shown below: No. of Breakdowns Frequency in days 0 1 2 3 4 40 150 70 30 10 300 The firm estimates that each breakdown cost Rs.650/- and is considering adopting a Preventing maintenance program which would cost Rs.200 per day and limit the Number of breakdown to an average of one per day . What is the expected annual Saving from preventing maintenance program?
  28. 28. Solution To determine the expected number of breakdowns per year: No. of breakdowns (x) Frequency of Bds in days.f(x) Probability distribution of Bds P(x) Expected value of Bds. X.P(x) 0 1 2 3 4 40 150 70 30 10 40/300=0.133 150/300=0.500 70/300=0.233 30/300=0.100 10/300=0.033 Nil 0.500 0.466 0.300 0.132 Total 300 1.000 1.400 Total number of breakdowns per day = 1.400 Cost of breakdown per day = 1.40 * 650 = Rs.910/- Cost of preventing maintenance programmed per day = Rs.200 + Rs.650 = Rs.850/- Expected annual savings from the preventing maintenance program = (910 – 850) * 300 days = Rs.18,000
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