Maintenance Engineering (TIE 516) Module 1 Maintenance, maintainability and Maintenance considerations in engineering systems Module objectives At the end of this module, the students should be able to: + Define maintenance and distinguish ‘maintenance mission and maintenance function. between + Know the structure of a typical maintenance organisation and appreciate the differences in existing maintenance organisation model variants. + Know the importance of maintainability in effective and efficient equipment maintenance + Identify maintenance and maintainability related elements that are necessary for proper system design. Maintenance Engineer IE 516) Module 1 Topics (1) The maintenance function and organisation for efficient maintenance (2) Maintainability of man-machine systems and maintenance considerations in engineering systems design Topic 1: The maintenance function andMaintenance: Definition Maintenance is the combination of all technical, administrative, and managerial actions during the life cycle of an item or object intended to retain it in, or restore it to, a state in which it may perform its required function It can also be defined as all actions necessary for retaining an item or equipment in, or restoring it to, a specified condition. The Maintenance Mission and the Maintenance Function Maintenance: Definition (Contd.) It is the act of keeping, preserving, and protecting materials from failure or decline. Such materials include machine, equipment, plant infrastructures and systems. It usually involves actions to * control or prevent the deterioration process leading to failure of an engineered object * Restore the object to its operational state through corrective actions after a failure. iaintenance mission The task of undertaking maintenance on engineering objects to ensure that the desired equipment state or conditions is achieved is usually the responsibility of a maintenance department or group. For any competing organisation, the maintenance mission (or end goal) of a typical maintenance department should involve the following; a) Optimum availability: The primary function of the maintenance organization is to ensure that all machinery, equipment, and systems within the plant are always available and in good operating condition.b) Optimum operating conditions: All direct and _ indirect ‘manufacturing machinery, equipment, and systems must be continuously maintained so that they will be in optimum operating ‘condition. © Maximum tization of maintenance resources: In the proces of voper equipment msntenanee, one goal. of the maintenance [rpunivation should be effective ue ofthese resources, 4) Optimum equipment fe: ‘The maintnance. organi can Inert pms tal wil care he al Heo a pe ©) Minimum spares inventory: Use of reduced spare inventory should be 2 major objective ofthe maintenance organization; however, the reduction should not impair ther ability to meet the ‘st four goals. Maintenance Function (cont ill, Installation of special services. iv. Alteration and modification of _ plant, equipment and buildings v. Alteration and modification of utilities and special service ©) Operation and supervision of particular ies and special services i. Boiler house operation, steam supply, power and generation ii, Compressed air plant and supply lines, heating and ventilation systems. Maintenance Function In attaining the maintenance mission, the various maintenance activities required to be carried out in an organisation by the maintenance department is referred to as its maintenance function. These functions include: a) Pure maintenance activities: maintenance of existing plant, equipment and buildings ii. Rebuilding and reconditioning of old plan and equipment b) Installation and alteration of plant, equipment and services i. Installation of new plant and equipment ii. Installation of utilities e.g steam, ventilation ete, Maintenance Function (contd. d) Miscellaneous duties i. Factory and site cleaning services ii, Waste and effluent disposal ili, Salvage collection and disposal iv. Fire fighting services v. Factory securityMaintenance Function (cont Operational implication of maintenance function i. The engineering object must be available when required ii, The plant, equipment or infrastructure must operate efficiently at the required production level Downtime for maintenance must not interfere with the production schedules iv. Downtime due to breakdown must be minimal aiesane ranapementfcins ang Ingemetirg catalig Grabandcbetes Waraemantyten Peromacemessues anda ‘gure I: Management Fuetions Organisation for efficient maintenance The effectiveness of maintenance actions depends on many maintenance management functions (Figure 1). These functions are affected by the overall goal of the organization and the overall organizational set-up. Organisation for efficient maintenance Maintenance organization involves the translating of plans into reality by deciding where decisions will be made, who will perform what tasks, and who will report to whom in the organization. Organizing effectively leads to better coordination of human, material, and information resources.Organisation for efficient maintenance Maintenance organization structure ‘A maintenance organization structure may be considered as a hierarchy of work roles, ranked by their authority and responsibility for deciding what, when, and how maintenance work should be carried out. Organisation for efficient maintenance (Contd. 2. Establishing the relationships, both vertical and horizontal, between individuals in the maintenance organisation. 3. Ensuring that the maintenance objectives are aligned with business objectives and are well understood by each individual in the maintenance organisation. 4, Establishing effective systems of coordination and communication vertically and horizontally in the ‘maintenance organisation. Organisation for efficient maintenance Design of a maintenance organization ‘The design of a maintenance organization structure involves the following: 1, Determining the responsibility, authority, and work role (the deci maintenance organization. jon-making bounds) of each individual in the Organisation for efficient maintenance (Contd.) A good maintenance organization provides clear roles and responsibilities, an effective span of control for facilitation of good supervision, effective reporting, and a continuous improvement culture. In addition, the maintenance department has to establish strong coordination, cooperation, and communication with the production/operation departments (its main customers) Such coordination should start at the top level and continue to the lower levels of the organization, Responsibilities are required of both the operators and managersOrganisation for efficient maintenance (Contd.) Requiring the support of all departments involved in the use of the equipment or facility will ensure full cooperation and understanding of affected departments, Thus maintenance organization is important. Figure [Link] When planning a maintenance organization, the following guidelines may be considered: 1. The maintenance organisation should be created to fit the individuals involved in the maintenance activities. 2. Aclear division of authority with minimal overlap should be established among maintenance organisational units 3. Vertical lines of authority and responsibility should be kept as short as possible Organisation for efficient maintenance (Contd, 4. The number of people reporting to an individual must be optimised. ‘Types of maintenance organisations (Centralized (ii) Decentralized (iii) Hybrid (i Centralized maintenance organization (CMO) In the centralized maintenance organization, the maintenance management function is centralized through the maintenance manager, who is responsible for all aspects of plant and facility maintenance and support. Almost all services are dispatched from a central location and all spares and materials are issued from the central stores. Organisation for efficient maintenance (Contd.) Organisation for efficient maintenance (Contd.) Advantages of CMO ‘The advantages of this arrangement include: 1. More flexibility and better utilization of resources such as highly skilled technicians and special tools and equipment, 2. Better supervision and on-the-job training 3. Less investment in expensive modern equipment. Disadvantages of CMO 1. Lower productivity, as more time is spent on travel due to the remoteness of certain job locations for geographically dispersed facilities; 2. Less specialization on complex production units; 3. Less integration with operational units.