3. Module 2: Industrial / Plant
Maintenance Management
Overview
METE40F – Mechanical Engineering Technical Elective
Industrial Maintenance Management Module No. 1
Lecturer: Engr. Jameson R. Almedilla, MEng
Mechanical Engineering Department
Xavier University – Ateneo de Cagayan
4. • Industrial and Plant Maintenance Programs and
Activities
• Basic Type of Maintenance Activities
• Maintenance Planning and Scheduling
• Control of Maintenance
• Sample of Common Maintenance Works
Topic Outline
5. Objectives for the discussions;
By the end of the discussions; students should be able to;
Know the basic types of maintenance activities
Understand the concepts of Maintenance Planning
and Scheduling
Understand the controls of maintenance programs
Learn some common maintenance activities
7. How Maintenance Activities are Managed?
Maintenance activities can be managed by;
Organizing Team
Programming Activities
Planning Activities
Establishing Work Flow
Creating Procedures
Controlling Costs/Finance
8. Basic Types of Maintenance Activities
These are some of the Basic Types of Maintenance;
1. Preventive Maintenance (PM)
2. Predictive Maintenance or Condition Based
Maintenance (PdM)
3. Corrective Maintenance (CM)
4. Reactive Maintenance (RM)
5. Redesign and Modification
6. Reliability Centered Maintenance (RCM)
9. Planning
Planning of maintenance jobs basically deals with
answering two questions, ‘what’ and ‘how’ of the job; ‘what
activities are to be done?’ and ‘how those jobs and activities
are to be done?’
Maintenance Planning & Scheduling
12. Steps of Job Planning
Knowledge
base
• It includes knowledge about equipment, job, available techniques, materials and
facilities.
Job
investigation
at site
• It gives a clear perception of the total jobs.
Identify and
document
the work
• Knowing the earlier two steps and knowing the needs of preventive, predictive and
other maintenance jobs.
Development
of repair plan
• Preparation of step by step procedures which would accomplish the work with the
most economical use of time, manpower and material.
Preparation
tools and
facilities list
• Indicating the needs of special tools, tackles and facilities needed.
Estimation of
time required
to do the
• with work measurement technique and critical path analysis.
13. Scheduling
Scheduling
Scheduling is the function of coordinating all of
the logistical issue around the issues regarding the
execution phase of the work. Scheduled of
maintenance jobs basically deals with answering two
questions— ‘Who’ and ‘When’ of job,
i.e., “who would do the job” and “when the job would
be started and done”.
14. Scheduling
Maintenance Schedule Technique:.
1. Weekly general schedule
is made to provide weeks’ worth of work for each employee in an area.
2. Daily schedule
is developed to provide a day’s work for each maintenance employee of the
area.
3. Gantt charts
are used to represent the timings of tasks required to complete a project.
4. Bar charts
used for technical analysis which represents the relative magnitude of the
values.
5. PERT/CPM (Program Evaluation and Review Technique/Critical Path Method)
are used to find the time required for completion of the job and helps in the
allocation of resources.
15. Planning and Scheduling Contributes
Effective Planning and Scheduling contribute
significantly to the following;
Reduced maintenance cost
Improve utilization of the maintenance workforce by
reducing delays and interruptions.
Improved quality of maintenance work by adopting the
best methods and procedures and assigning the most
qualified workers for the job.
21. Control of Maintenance
By requirements:
How are maintenance activities being controlled at a
desired output?
o Authorization (Authorized by and official)
o Maintenance Plan and Schedule
o Issue of Materials against proper authorization
o Maintenance Budgets
o Equipment Records
22. Control of Maintenance
By critical questions:
Along maintenance activities, here are some issues that can be met
o How much maintenance is needed?
o What size of maintenance crews must be used?
o Can maintenance be sub-contracted?
o Should maintenance staff be covered by wage incentives schemes?
o Can effective used be made of computers for analyzing and scheduling
activities?
24. Common Maintenance Activities
1. Repair Activities
To fix or to mend (a thing that
is suffering from damage or
fault)
Examples:
Equipment Overhaul
Car Repair
Rectification of damaged
components
Tapping/Welding of holes
Alignment of pumps
Hot bolting
Pipe/Spool Replacement
25. Common Maintenance Activities
2. Lubrication
Process of adding lubricant
(grease or oil) to a solid-solid
contact.
The reduced friction leads to less
wear, heat generation and
energy loss – all of which reduce
operation costs and downtime.
Cooling and debris removal are
the other important benefits
provided by a fluid lubricant.
27. Common Maintenance Activities
3. Calibration
Comparison between two
measurements one of known
magnitude or correctness made or
set with one device and another
measurement made in as similar a
way as possible with a second device.
The device with the known or
assigned correctness is called the
standard. The second device is the
unit under test, test instrument, or
any of several other names for
the device being calibrated.
30. References
1. Roy Zapata (2015). Basic Concepts of Maintenance 1 and 2. Education and Training Technology Unit,
Center for Industrial Technology and Enterprise (CITE) Cebu City.
2. B.S Dhillon (2002). Engineering Maintenance: A Modern Approach. CRC Press LLC
3. S. Kumar & N.Suresh (2008, 2nd Ed.). Production and Operations Management, Chapter 8:
Maintenance Management. New Age International Publishers.
4. Online References:
a. http://maintenanceworld.com
b. http://www.engineeredsoftware.com
c. http://www.plantservices.com
d. http://www.lifetime-reliability.com
e. http://reliabilityweb.com
f. http://www.maintenanceonline.co.uk
32. Assignment No. 1
Essay:
1. Discuss your perspective of Maintenance
Management. (20 pts)
2. Explain how Maintenance Planning and Scheduling
will influence your management style? (20pts)
3. Share your thoughts on the ways of controlling
maintenance. (20 pts)
4. Aside from the common maintenance activities
shared from this discussions, discuss an another
one maintenance activities you may know. (20 pts)
