The document discusses maintenance and occupational safety. It defines maintenance as actions taken to retain or restore equipment to a working state. Preventive maintenance aims to avoid failures through scheduled repairs and is more cost effective than corrective maintenance, which only fixes existing issues. The document also outlines various occupational hazards for maintenance workers like noise, vibration, and exposure to hazardous substances. It recommends enforcing protective equipment, risk assessments, safety information, and injury prevention programs to promote occupational safety.

1. MAINTENANCE
AND
OCCUPATIONAL SAFETY
BY
ERINLE BABATUNDE.O

2. HOW RICH ARE YOU?
 Net worth: Value of machines minus liability
 Spending: Cost of repair, cost of parts
 Savings: Income minus spending
Maintenance should always be an active part in
an organization so as to maintain spending
margins and keep the company running
effectively.
0
5
10
15
20
25
RICH AVERAGE BROKE
SPENDINGS SAVINGS NET WORTH

3. Maintenance may be defined as the combination of
all technical, administrative and managerial actions
during the life cycle of an item, intended to retain it
or restore it to a state in which it can perform it’s
required function.
A maintenance function is critical t0 the following;
 Ensuring continuous productivity
 Producing products of high quality
 Maintaining a company’s competitiveness

4. TYPES OF MAINTENANCE
The primary goal of maintenance is to mitigate
the consequences of failure of equipment.
The types of maintenance includes:
 Preventive maintenance
 Corrective maintenance

5. PREVENTIVE MAINTENENCE
An operation carried out in an
attempt to avoid failures,
unnecessary production loss
and safety voilations.
It is designed to preserve and
restore equipment reliability
by replacing worn
components before they
actually fail.

6. CORRECTIVE MAINTENANCE
An operation performed to
identify, isolate and rectify a
fault so that the failed
equipment, machine or
system can be restored to an
operational condition within
the tolerances or limits
established for in-service
operations.

7. DO WE REALLY NEED PM?
“Sure, I know preventive maintenance helps to
avoid unplanned downtime and breakdowns. But
PMs takes time excessively and cost a lot of
money, and they don’t seem to make that much
difference in the way our equipment runs. We’ve
got excess capacity anyway, and we’re not running
production on all shifts during the week. So,
the downtime and repairs aren’t costing us that
much in lost production. We’re able to keep up
with customer orders. I really don’t see why we
need to spend time and money on PM program.

8. COST!!, THEN WHY SHOULD PM
BE PRACTICED?
The general problem associated to preventive
maintenance is cost.
The system can seem difficult and time consuming,
but there are solutions that can help;
 Utilizing computerized maintenance management
software
 Control monitoring
Remember, ”you cannot cut cost your way to
profitability”.
"You need to be rich to buy cheap products. Why?
Because you eventually have to buy twice to have the
job done properly." -Tunde.

10. PREVENTIVE OVER CORRECTIVE MAINTENANCE
Preventive maintenence makes good business
sense. How?
 Saves cost
Reduces spoilage
Decreases downtime
Decreases revenue loss
Improve reliability
On the other hand, reactive maintenance slumps a
business contingency. How?

11. Difficult to control budget
Time consuming
Safety issues
Interfers with planned work
Issue repetition
Maintenance is not all about fixing things that
break, it is all about preserving, protecting,
safeguarding, and looking after the very machines
that make business possible.

12. MAJOR PRODUCTION EQUIPMENT
IN VITAFOAM NIG.
NO. OF MATTRESS
PRODUCED PER
DAY
1800
NO. OF TAPE EDGES 10
NO. OF SHIFTS 2
WORKING HOURS
PER SHIFT
8HRS
TOTAL NUMBER OF
WORKING HOURS
16HRS
ESTIMATED
FAILURE RATE
65%
LIFE SPAN 10 YEARS

13. PMs CMs
CLEANING
 
INSPECTION
 
LUBRICATION
 ×
OVERHAUL
BEFORE
FAILURE  ×

14. DOWNTIME
64%
CMs
25%
PMs
11%
DOWNTIME
CMs
PMs

15. Downtime
market
share holders
0
1
2
3
4
5
6
7
8
9
10
YEAR 1 YEAR 2 YEAR 3 YEAR 4
EFFECT OF EXCESSIVE DOWNTIME
Downtime market share holders

16. BUT, WHEN SHOULD CM BE USED?
Reactive maintenance should only be performed on
components that are inexpensive, easy to replace,
where the failure does not cause collateral damage
in the system or where the cost of reactive
maintenance is not greater than preventative
maintenance.

17. COST OF MAINTENANCE ON CAPITAL
INVESTMENT RETURN
The cost of maintenance can send your business
broke. If your annual maintenance cost is higher
than 5% of your asset value you are in trouble.
Total Maintenance Cost per RAV (%) = [Total
Maintenance Cost ($) × 100] ÷ Replacement Asset
Value ($)
The total maintenance cost depends on the quality
of the equipment used and how much
maintenance it requires.

18. PROBLEMS OF MAINTENANCE OPERATIONS
Problems associated to maintenance operations
includes;
 Poor schedule compliance
 Lack of management support
 Skill gap
 Insufficient detail on maintenance record

19. LIMITATIONS TO MAINTENANCE IN VITAFOAM NG.
PLC
Problems associated with maintenance in
vitafoam Ng. Plc includes;
 Wrong equipment selected
 Inconsistency
 Poor documentation after repair
 No changing/updating of maintenance system
 Non availability of critical parts for machines
 Privation of trained personnels

20. RECOMMENDATIONS
The following can be done to ensure proper
maintenance exercise.
 Introduce 5-whys analysis
 Plan
 Set data operating instructions
 Use of computerized maintenance management
system (CMMS)
 Use of control monitoring
 Training and competence

21. CONCLUSION
In this tough economic times, it makes sound
business sense to improve preventive
maintenance effectiveness. Businesses that ignore
the advantages and profitability of preventive
maintenance will continue to struggle and miss
their true potential in the marketplace.

22. 0
5
10
15
20
25
YEAR 1 YEAR 2 YEAR 3 YEAR 4
IF VITAFOAM ABOLISH CORRECTIVE
MAINTENANCE SYSTEM
CM PM SAVINGS PROFITABILITY

23. Vitafoam Nigeria plc, which is one of the leading
manufacturing industries in Africa, should abolish
the corrective maintenance system and
implement the preventive maintenance system
so as to hoist its productivity and compete in the
international market.

24. SAFETY
Safety is the state of being "safe“.
This is the condition of being
protected from harm or other
non-desirable outcomes in order
to achieve an acceptable level of
risk.

26. OCCUPATIONAL HARZARDS
AND INJURIES

27. OCCUPATIONAL HAZARDS IN
VITAFOAM NIG. PLC.
Maintenance workers are exposed to many and
varied risk when carrying out their job due to very
different activities of maintenance.
These hazards includes the following;
Physical hazards
:Noise
:Vibration
:Musculoskeletal disorders (MSDs)
 Biological hazard
:Exposure to legionnaires
:Exposure to cancerous substances

28. SAFETY RECOMMENDATIONS IN
VITAFOAM NIG. PLC.
The following can be done to ensure proper
maintenance exercise.
 Enforce protective equipment
 Risk assessment should be carried out
 Adequate information should be given
 Having programs to prevent MSDs

30. ALWAYS BE CAREFUL