Dr.

Chaminda Karunasena
Senior Lecturer, Dept. of Mechanical & Manufacturing Engineering,
Faculty of Engineering, University of Ruhuna.
E-mail : chaminda@[Link]
Web : [Link]
LinkedIn : [Link]
 Basic Understanding on Maintenance Management
and Maintenance Dept. Activities (3 hrs)
 Different Types of Maintenance Techniques Available (3 hrs)
 Maintenance KPIs (3 hrs)
 Standard Maintenance Analysis Techniques (3 hrs)
 Maintenance Communication Systems (3 hrs)
 Introduction to Autonomous Maintenance (3 hrs)
 Introduction to TPM (3 hrs)
 Approach of Improving An Existing Plant Maintenance System (6 hrs)
 Concept of KAIZEN (2 hrs)
 Non Destructive Testing Techniques (2 hrs)
 Introduction to 5S Concept (3 hrs)
 Introduction to ISO Quality System (3 hrs)

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 Continuous Assessments – 40%
 20% by two individual assignments
 15% by group assignment and presentation
 5% Field visit participation
 End Semester Examination– 60%
 Necessary conditions for a student to be eligible to appear for
the end semester examination :
 Earn at least 80% attendance for theory classes
 Complete all assignments/ field visits
 Necessary Conditions to pass the Module:
 Achieve at least 50% of marks from continuous assessments
 Achieve at least an overall mark of 40% with a minimum of 30% in the End
Semester examination
 Reference Text Books:
 Engineering Maintenance: a modern approach by Dhillon, B.S., CRC Press.
 Industrial maintenance management: by Srivastava, Sushil Kumar, New Delhi: S. Chand.
 Practical plant failure analysis: a guide to understanding machinery deterioration and improving equipment
reliability by Sachs, Nevile W, CRC Press.
 Reliability-centred maintenance: by Moubray, John, Oxford: Butterworth.
 Industrial engineering and production management: by Tompkins Telsang, Martand, New Delhi: S. Chand.

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 Usethese tools in industry as engineers to
improve the a given maintenance system and
create impact to the organisation

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 Maintain plant machinery with minimal breakdowns and
to overcome possible production/ service/ safety issues
 Do what ever to eliminate breakdowns
 Fire fighting like behaviours within maintenance dept.

 Maintain plant machinery to cater a given production or

service process at required availability with minimal
cost
 Always focus to improve the existing system day by day

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 Ensure the maximum availability of the
production or services machines, as planned
 Maintain product or service quality within
accepted levels
 Minimise losses and wastages of energy,
resources(machines or material), man power
 Ensure safety and work friendly environment
 Minimize overall O&M cost of the plant
 Can create new business opportunities
 Provide foundation for “Lean” transformation

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 Engineering

Maintenance
Dept.

Production

Human
Quality Resource

Purchasing/
Planning Stores

Sales

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 Maintenance
Manager

Maintenance
Engineers/
Executives

The Tertiary and

Junior Engineers Vocational Education
Commission (TVEC),

Assistant Engineers/Technical
Officers/Draftsmen

Technical Supervisors

Skilled Technicians(Mechanical/ Electrical/Hydraulic)

Semi-skilled Technicians/ Support personal

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 Day-to-day maintenance of plant machinery
 Industrial services:
 Generators
 Boilers
 Compressors
 Central HVAC
 Cooling Towers
 Building management systems(BMS)
 Vehicle maintenances :
 Material transport vehicles
 Passenger transport vehicles
 Small/ medium scale fabrication and installation of
machinery
 Other unplanned or spontaneous maintenance service
requirements from other sections of the plant
 Waste recycling unit

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 Mechanical/Hydraulic Electrical/Electronic
Workshop Workshop

Engineering Mnt.
Dept. Engineering
Office
Stores

Machine Shop Tool Stores

Quality
Assurance
Dept. SHE dept.

Production Dept.
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Planned Unplanned
Preventive Mnt. Breakdown Mnt.

Condition Monitoring and

Opportunistic Mnt.
Predictive Mnt.

Machine Check/Health
Check

Corrective Mnt.

Shutdown Mnt.

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Planned Unplanned
Preventive Mnt. Breakdown Mnt.

Condition Monitoring and

Opportunistic Mnt.
Predictive Mnt.

Machine Check/Health
Check

Corrective Mnt.

Shutdown Mnt.

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 “Maintenance Activities Conducted in a Routine
Manner to Ensure Prevention of Breakdowns”

Eg.
Cleaning of machine parts:
dust filters, panel boards, machine exterior, VSD circuit
board cleaning
Changing of lubricants/coolants :
engine oil change, water drainage of pneumatic lines,
boiler blow down
Replacement of spare parts:
bearings, brake liners, ELCBs
Observing conditions of machine parts:
leak detection in hydraulic lines, electrical contactor
point condition checking, motor megger testing

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Courtesy : Loadstar(Pvt.)Ltd. 14 of 27
 Body
Machine cleaning washing/teeth
brushing

Water drinking
Oil change
and urinate

Condition Annual
monitoring of body/dental
machine parts checkup

Natural removal
of old cells and
Replacement of
creation of new
spare parts
cells, kidney
replacements

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Time based Usage based Condition based

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 Schedule & conduct PM activities based on
repetitive calendar days or clock times
E.g.
Daily adjusting the settings
Weekly monitor the oil level
Monthly greasing the bearings
Yearly checking the vibration
 App. 80% of routine maintenance activities are
conducted under time based schedules
 “Time Span” is determined by
• Condition, criticality of the machine by refering to machine
manuals and past performance records
• Availability of the machine
• Availability of the maintenance resources
• Cost benefit analysis

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 Sample “Time Based” PM schedule of an industrial
material transferring conveyor

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 PM is conducted based on a measurement of the
machine utilization
 Once the number of allowable operation life time
exceeds, a PM is scheduled
E.g.
❑ Change engine oil of an automobile engine after 3000 km
❑ Replace diesel injector nozzle after 10,000 hrs of operation
❑ Fully service the hub motor/gear box assembly of an electric bike
after 3000 hrs of operation

 The allowable life time is to be decided base on

manufacturer recommendations (machine manual) or
after a throw study on machine operation history
 For economic benefits, “time based” replacement
activities may be reviewed based on calculated risk
and condition monitoring means

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 Sample“Usage Based” PM schedule of a
1500 kVA generator

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 PM is scheduled based on evaluating conditions of
machine components or other machine-related
substances
 Once the condition measured exceeds the
recommended value, the maintenance is done
accordingly
E.g.
 Most machine components are visually checked for wear or
deformations and replaced accordingly
 Boiler blow down is conducted based on conductivity
measuring of the boiler water
 A bearing is replaced once the vibration level exceeds the
recommended set limits
 Generator lubrication oil is changed after measuring the
viscosity, colour, PPM level and etc.

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 Condition monitoring is typically scheduled as
repetitive activities (time based) and maintenance
are done based on observed conditions
 In some cases Condition Based PMs are done totally
by perceptions of abnormalities
E.g.
▪ Abnormal noise of a bearing, gear box or belt
▪ Abnormal overloading of an electric motor
▪ Abnormal temperature rise of coolant fluid

 Sample “Condition based” PM schedule of a 1500 kVA

generator

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1. Overall “PM” Schedule/ Annual “PM” Plan Of The Plant

 All “time based”, ”usage based” and ”condition based” techniques are
included/ considered for this overall scheduling

 Other departments are involved in the scheduling process in order to

ensure year around schedule adherence
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2. PM Activity List
o Technical data on what & how maintenance activities are to be
conducted

3. Frequency of PM Activity
o Individual frequencies of each activity

4. Time Durations For Each Activity

o Allowable time periods for each activity in order to complete the
PM on time

5. Tools Needed
o Objective is to reduce tool searching time
o Ensure availability of critical tool for the maintenance functions
o Use of Correct tools for tasks

6. Spare Part Data

o What are the spare part specifications for each replacement
o Availability of spare parts in-time to complete maintenance
activities as scheduled

7. Details On Mnt. Crew Requirements

o What skill levels needed for each job requirement
o No. of heads needed for each task
o Help to manage the available manpower to cater the overall PM
program

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Courtesy of Loadstar(Pvt.)Ltd.
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7. PM Pre-evaluation record sheets
o Used to gather data on existing faults of the machine to be corrected
at the PM
o Mostly the people relates with the production/QC/SHE provide data
o Data collection should be carried out well prior to the PM

8. PM Post-evaluation record sheets

o Used to evaluate the impact from the PM to machine performance
o Production executives, supervisors, operators certifies the
performance

9. Spare part Kanban systems and EPR systems for activities

related with engineering stores

Spare Part Kanban Post SAP ERP Interface for Spare Part
Transactions
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 [Link]
 [Link]
 [Link]
 [Link]
 Loadstar(pvt.)Ltd. Maintenance Management Program and resources
 [Link]

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