PQRM-Maintainability-Availability

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

2. MAINTENANCE-EFFECTS
■ Right type of maintenance policy-required else may lead to either over
maintenance or under maintenance
■ Equipment Life-depends on nature and maintenance function
implemented in industry. Good maintenance policy increase life of
equipment
■ Maintenance-relates to targets and reliability of equipment
■ Proper selection of skilled, semi-skilled and unskilled labour should be
with proper division of responsibilities.

3. PRODUCTIVITY, QUALITY,
RELIABILITY AND MAINTAINABILITY(PQRM)
■ PQRM- important aspects for profitability of any industry
■ Each one has different role and affect performance of others
■ Productivity:
 Measure of economic efficiency which shows how effectively
economic outputs are converted into outputs
 Measurement-by comparing amount of goods and services produced
with the inputs which were used for production
 Labor productivity-ratio of output of goods and services to labor
hours devoted to the production of that output
 Productivity-shows changes from period to period in amount of
goods and services produced per hour

4. PRODUCTIVITY, QUALITY, RELIABILITY
AND MAINTAINABILITY(PQRM) Ctd.
 Productivity-reflect joint effects of many influences, like capital
investment, level of output, utilization of capacity, energy and
materials.,managerial skill etc
■ Maintenance Productivity:
 Mostly a group activity-hence difficult to define
 Productivity to be measure for whole dept. or a fixed group who
always remain together when on work or individual maintenance
worker basis
 Different industries attempt their own metrics to indiciate change in
maintenance productivity

5. PRODUCTIVITY, QUALITY, RELIABILITY
AND MAINTAINABILITY(PQRM) Ctd.
 Parameters for that are:
 Downtime due to failure-highest expenses
 Downtime due to maintenance itself
 Cost of manpower
 Spare parts, stock expenses
 Tools, instruments, room, transport, soft for maintenance
 Equipment condition-very sophisticated parameter
 These matrices-converted in rupees and a base value is worked out
■ Maintainbaility-key factor for maintenance productivity

6. PRODUCTIVITY, QUALITY, RELIABILITY AND
MAINTAINABILITY(PQRM) Ctd.
■ Quality:
 It is the ongoing process of building and sustaining relationships by
assessing, anticipating and fulfilling stated and implied needs.
 In industries-it is the extent to which products, services, processes
and inter-relationships are free from defects, constraints and items
which do not add value for customers and commodity conforms to
standards applied to said commodity by mechanical or other
standards.
 Quality can be static or dynamic
 Static-keeps in the industry
 Dynamic-to excel or win it

7. PRODUCTIVITY, QUALITY, RELIABILITY
AND MAINTAINABILITY(PQRM) Ctd.
■ Quality Circle(QC) in Maintenance:
– Emplies development and use of skills, capabilities and creativity of
people through cumulative process of education, work experience
and participation etc to solve their problems.
– Quality Circle-consist of small group of employees doing similar
work, who meet regularly on regular basis for analysing and solving
work related problems
– QC-capturing creative and innovative power that lies within work
force
– Provide self-motivation and happiness in improving environment
without any compulsion or monitory benefits

8. PRODUCTIVITY, QUALITY, RELIABILITY
AND MAINTAINABILITY(PQRM) Ctd.
■ Objectives of QC-change in attitude, self development, development of
team spirit and improved organizational culture etc.
■ Quality maintenance-help managers and other concerned persons to
develop , formulate and use quality indicators for maintenance
management/functions
■ Quality aspect in maintenance function is beneficial in following ways:
– Gain insight into how maintenance function can be made more
reliable, more cost effective and more efficient
– Compare maintenance information systems with other good systems
of your industry or other industries
– Align your maintenance program with you TQM initiatives

9. PRODUCTIVITY, QUALITY, RELIABILITY
AND MAINTAINABILITY(PQRM) Ctd.
■ Monitor processing techniques
■ Keep control check with replacement and life cycle cost
■ Use of QAMM(Quality Assured Maintenance Management)
■ Total Quality Preventive Maintenance Programmes which prology life,
improve equipment safety and reliability , reduce cost of major repairs
and minimize inconvenience of equipment downtime etc.

10. PRODUCTIVITY, QUALITY, RELIABILITY
AND MAINTAINABILITY(PQRM) Ctd.
■ Reliability:
– Focuses in ability of a product to perform its intended function.
– It can be defined as the probability that an item will continue to perform its
intended function without failure for a specified period of time under stated
conditions
– Product could be an electronic or mechanical product, component
hardware, a software product etc.
– Reliability Engineering is the application of reliability concept in
engineering or industries and in more concerned with basic reliability.
– It covers all aspects of product’s life-from its conception, subsequent design
and production process as well as through practical use lifetime

11. PRODUCTIVITY, QUALITY, RELIABILITY
AND MAINTAINABILITY(PQRM) Ctd.
■ Reliability is important for
– Reputation of the company/industry
– Customer Satisfaction
– Warranty Costs
– Repeat Business
– Cost Analysis
– Customer Requirments
– Competitive Advantage

12. PRODUCTIVITY, QUALITY, RELIABILITY
AND MAINTAINABILITY(PQRM) Ctd.
■ Difference between Reliability and Quality
Reliability Quality
Concerned with performance of a
product over its entire life time
Concerned with performance of a
product at one point in time
Assures components,equipments etc
function without failure for desired
periods during whole deisgn life
Quality control is a single, albeit vital,
link in total reliability process
Quality control assures conformance to
specifications and incoming parts and
components meet specifications.

13. PRODUCTIVITY, QUALITY, RELIABILITY
AND MAINTAINABILITY(PQRM) Ctd.
■ Maintainability:
– Ease with which a system or component can be modified to correct
faults, improve performance or other attributes or adapt to a
changed environment
– Defined as ease in time and resources of retaining equipment in or
restoring it to a specified operational condition.
– Also be defined as measures taken during design, development and
installation of a manufactured product that reduce required
maintenance, man-hours , tools , logistic costs
– Important aspect of any system’s lifecycle.