Maintenance?
Synonym?
Maintenance vs Repair
Maintenance, then and now
Many years ago, the manufacturing and production
work was done with relatively simple technical
equipment and the involvement of more manpower.
Maintenance was of course simple and impact to
certain extent to the function of machines.
During the industrialization, production equipment
has been more developed. In connection with the
high technical development the impact of
productivity and quality has moved from man to
machine.
The importance of maintenance has considerably
increased.
There are many reasons why maintenance is
becoming more and more important. In developing
countries , where many old machines are operating,
the spare part problem are arising. Some times it is
difficult to find spare parts for equipment and if it
is possible to find them, they are usually very
expensive and must be paid on foreign currency.
Due to long lead times of supply of spares, it is
common that the spare part inventory is growing
bigger than necessary. A very essential part in
maintenance management is developing countries to
reduce the need of spare parts, as well as to
maintain the minimum level of shock to save foreign
currency, but still keeping the productivity high.
• Plant maintenance is an important
service function of an efficient
production system.
• It helps in maintaining and increasing
the operational efficiency of plant
facilities.
• Maintenance is the procedure of finding
the faults in any equipment/Machine and
also removal of fault.
• It may be before the breakdown or
after the breakdown.
• Plant maintenance usually refers to the
methods, strategies, and practices used to
keep an industrial factory running
efficiently. This can include anything from
regular checks of equipment to make sure
they are functioning properly.
• The general aim of plant maintenance is to
create a productive working environment
that is also safe for workers.
Definition
Maintenance can be considered as a combination of
actions carried out in order to replace, repair, service,
modify the components, or some identifiable group of
components, of a manufacturing plant so that it will
continue to operate to a specified availability or a
specified time.
Maintenance is the totality of all measures
directed towards control (preservation and
restoration) of the performance of a plant.
Maintenance is an auxiliary process in a production
process directed towards a high effectiveness of the
main process.
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The Importance of
Maintenance
Industrial maintenance has two essential
objectives:
• (1) a high availability of production equipment
and
• (2) low maintenance costs (Komonen, 2002).
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Maintenance Objectives:
• To increase functional reliability of
production facilities.
• To maximize the useful life of the
equipment.
• To maximize production capacity from the
given equipment.
• To minimize the total production cost.
• To minimize the frequency of interruption
in production by reducing breakdowns.
• To enhance the safety of the manpower.
OBJECTIVES OF MAINTENANCE
Elimination Prevent
of future breakdown
defects during operation Ensure safety
during
prevent rapid operation
wear of
components
Productivity Improvement
through maximum
availability at
Enhance optimum cost
performance
level Maximize
operational
Reduce Reduce idle hours efficiency
maintenance due to component
cost malfunctioning
Importance of maintenance
• It helps in identify the cause of failure ,
e.g whether the failure is due to design
defect, or a wear out failure.
• It also helps in deciding the type of
maintenance and maintenance decision like
replace and repair.
• It provides the necessary information
regarding the life and reliability of the
equipment.
• With the help of this tool spare parts
management got initiated.
Maintenance Activities
Activities of maintenance function could be
either repair or replacement activities, which
are necessary for an item to reach its
acceptable productivity condition and these
activities, should be carried out with a
minimum possible cost.
Maintenance activity is the systematic and
scientific upkeep of equipment for:
Prolonging life of the equipment,
Assuring instant operational readiness,
Optimal availability for production at all times, and
Making sure that safety of man and machine
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History/Trends of Maintenance
According to John Moubray (Reliability-Centered
Maintenance), the evolution of maintenance since the
1930's can be traced through three generations
based on three technical factors:
a) First Generation
b) Second Generation, and
c) Third Generation
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First Generation
This covers the period up to the World War II.
Maintenance activities during this era thus got to be known as
“breakdown maintenance” and arose only when the equipment or
processes were not functioning or were shut down because
they were producing unacceptable output or were unsafe to
operate.
During this period:
- industry was not highly mechanized,
- equipment was simple and over designed,
- downtime did not matter much,
- prevention of equipment failure did not have
high priority,
- failures were corrected as they occur. 14
In the period of pre-World War II, people
thought of maintenance as an added cost to
the plant which did not increase the value of
finished product.
Therefore, the maintenance at that era was
restricted to fixing the unit when it breaks because
it was the cheapest alternative
As a result, there was no need for systematic
maintenance beyond cleaning, servicing and
lubrication.
THE FIRST GENERATION
Average Farm Tractor
No. of tractors failing
Critical
Year / year per 1000
components
tractors
1935 1200 113
1960 2250 201
1970 2400 213
1980 2600 229
1990 2900 252
Second Generation:
During the war, demand for good increased and
supply of industrial outputs was low. This led to
increase in mechanization.
During this period:
Machines became numerous and more complex,
Industry started to depend heavily on these
machines,
Downtime started to matter,
The idea that equipment failures could and
should be maintained came up.
.
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During and after World War II at the time when the
advances of engineering and scientific technology
developed, people developed other types of
maintenance, which were much cheaper such as
preventive maintenance.
In addition, people in this era classified
maintenance as a function of the production system.
As a result, the concept of preventive
maintenance and maintenance planning and
control systems grew up
Third Generation:
Since the mid-seventies, new expectations, new
research and new techniques have revolutionized
maintenance.
During this period:
Maximizing life of equipment has become
important,
Higher plant availability and reliability have
become very important,
Greater automation has been effected,
Quality standards, safety and environmental
consequences matter quite a lot,
Cost of maintenance is becoming central,
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Nowadays, increased awareness of such
issues as environment safety, quality of
product and services makes maintenance one
of the most important functions that
contribute to the success of the industry.
World-class companies are in
continuous need of a very well organised
maintenance programme to compete world-wide.
As a result: greater expectations and leading
to new research which in turn lead to new
techniques.
Development of
Maintenance
-Increased awareness of:
Fix the - Environment
equipment -Safety
when it breaks -Quality
-Need for reliable equipment.
-Reduction in costs.
Time
Pre-World War II Post-World War 1980 Onwards
II
Maintenance History
(Adapted From Shenoy, Bhadury 1998)
Modern maintenance management is not to
repair broken equipment rapidly. Modern
maintenance management is to keep the
equipment running at high capacity and
produce quality products at lowest cost
possible.
WHAT IS FALIURE ?
Digress /Deviate of demands of a certain
quality
Why Machines Fail
- Tools or dies wear out by friction with the work
piece
- Machines parts wear out by friction with one
another
- Atmospheric conditions destroy the machine
points and materials.
- Aging also affects materials
- Improper handling of materials affects
equipment and material
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INDIVIDUAL LIFE TIME
Machines, spare parts, all types of equipment,
have their own individual lifetime. The individual
life time is different from part to part and is
influenced by the quality of the product but
also by other outside factors such as
environment, handling etc.
Some failures are occurring after a certain,
expected time, and can almost be predicted.
Some failures are occurring completely
unexpected.
FAILURES
Random Regular
Failures Failures
Non-Predictable Predictable
General classification Maintenance problem.
Mechanical Failure
Worn out bushes and bearings and other moving parts.
Fatigue of machine members
Creep of material at high temp
Excessive forced vibration, misalignments etc.
Thermal Failure
Overheating of the component
Lack of lubrication
Inadequate of cooling
Electrical insulation failure
Chemical Failure
Highly corrosive fluids containing abrasive particles
Failure of protective linings like glass , rubber etc.
Different type of maintenance:
Running
maintenance
Preventive Shutdown
Maintenance maintenance
Scheduled
maintenance
Planned
Maintenance Breakdown
Maintenance
Corrective maintenance
Maintenance Shutdown
Predictive maintenance
Maintenance
Unplanned Emergence
maintenance maintenance
Total Productivity Maintenance (TPM)
TPM is a way of organizing maintenance to
support productivity & quality through
increased equipment efficiency and to reduce
costs.
TPM concept means that all employees work
in small groups to maximize the improvement
of equipment efficiency.
Operators are working independently with all
maintenance activities of their own equipment
and have also the total responsibility of
operation and maintenance.
Maintenance has to be taken into consideration in
very early stage of work of procuring new
equipment to ensure a good and cheap operation.
High quality equipment will give high reliability
and maintainability which secure high
productivity and equipment efficiency.
The lifetime of the equipment can be sum up in
six phases
1. Idea/Need
2. Specification
3. Design
4. Procurement(Manufacturing)
5. Operation
6. Windup
Bath Tub Curve
The bath tub curve describes the cost of
equipment over its lifespan. From commissioning to
winding up.
Cost
100% Life Time
LCC – Life Cycle Cost – is commonly
understood to be the customer’s total
cost and other sacrifice during the actual
life time of the product. Hence LCC
includes the acquisition cost as well as all
future costs for operation and support of
the product until it is finally discard.
Comparison of alternative products.
Improvements of products.
Adaptation of the maintenance and
support organization.
Objectives of Maintenance
During the years the maintenance function has not been
seen as a condition for production output. The previous
approach has been that maintenance is the necessary evil,
one among the cost generators in the organization. Very
often the maintenance strategy in plants has been to
reduce the maintenance cost as much as possible without
thinking of the consequences.
Objective of the maintenance is , as priority one , to create
an availability performance which is suitable for production
demands in the organization.
1.
Keep up the planned availability performance
2.
At the lowest cost
Above all
Within the safety prescriptions
All enterprises and organizations are interested in lowering
maintenance costs. A very common delusion is that
MAINTENANCE WICH IS NOT CARRIED
OUT ,WILL COST EVEN MORE THAN
MONEY !!!!!!
The maintenance cost can be split up in two
different categories.
The costs are directly related
Direct maintenance costs - to the performance of the
maintenance works
Indirect maintenance costs -Losses due to maintenanc
Direct maintenance costs
• Wages & Salaries
• Material Costs
• Administration Costs
• Costs for training
• Spare parts costs
• Contracted work forces
• Modification Costs
Indirect Costs
• Loss of revenue or other losses as a
result of interruption to production
as a result of maintenance.
Results in the correct maintenance work
is carried out
At the right time
In the right way
By the right professional
With the right spare parts
“Real maintenance management is impossible
without condition based preventive maintenance”
PLANNING
ANALYSIS PERFORMANCE
RECORDING
End