CHAPTER ONE
Maintenance of machinery
By : Waka A.
Sep. 2017 E.C
BONGA, ETHIOPIA
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Maintenance of machinery
Introduction to maintenance of machinery
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WHAT IS MAINTENANCE ?
❖ Maintenance is any activity that, is carried out on any facility
either to restore to or to retain the facility in a good and acceptable
working conditions.
➢ Maintenance involves all technical and other procedures performed
in order to retain the satisfactory working condition of a machine or
part (restoring it to an acceptable working condition) so that the set
tasks can be performed at the scheduled time and under given
conditions.
➢ Maintenance is often not given the priority it deserves in the overall
operating strategy of a facility.
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❖ Maintenance programs are managed and funded by people, and human
nature seems to abide by the old tenet, “If it isn‟t broke, don‟t fix it.”
Compared to other departments, maintenance departments have no real
“product” and - as such - produce no real income.
❖ Many managers view money spent on maintenance as money thrown
down a black hole.
• In spite of any life-cycle “proofs” to the contrary, managers look for ways
• to cut maintenance budgets first when any other need arises.
• It has been stated below that the maintenance functions stem at
supporting role to keep equipment;
(i) To operate effectively;
(ii) To maintain quality standard at all times;
(iii)October
To maintain
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the quantitative and cost standards of output. 4
• Manufacturing of goods is closely connected with the means of
production. Every means of production is, in closely connected with
wear and tear. A few examples are mentioned below.
– Tools or dies wear out by friction with work piece
– Machines parts wear out by friction with one another
– Atmospheric conditions destroy machine parts and materials
– Aging affects materials and their behavior
– Improper handling affects equipment and materials
• If proper action against these wearing out of equipment and materials is not taken,
there would be breakdown in the production processes, and materials deteriorate
unduly resulting in loss or, total stoppage of production. Hence, there is a
permanent necessity that all means of production be
✓ Used
✓ Checked
✓ Serviced
✓ Tended last (estimated life time)
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❖ In order to give the full function which they are designed for the last
three necessities constitute what is called maintenance, whereas the
former is operational.
❖ From the engineering point of view, the management of the means of
production has two elements. that are. First, it must be maintained,
and second, from time to time it may also need to be modified.
Other Definition of Maintenance
• The term maintenances is derived from the word maintain which
is defined is defined as
✓ Cause to continue or
✓ Keep in an existing state (according to Webster Dictionary)
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A means of production is made operational because the user wants to
do something i.e. the user expects the means of production to fulfill a
certain function. Therefore the means of production has to be preserved
in its existing state, or it must continue to function in its desired state.
Therefore in a non technical terms, maintenance may be defined as ensuring
that a means of production continue to function to accomplish what the user
wants it to do.
A comprehensive definition
Maintenance can be considered as a combination of action 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 satisfactorily to a specified availability or a specified
time.
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In other words, maintenance can also be defined as follows
• 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.
Trends in the Evolution of Maintenance
• According to John Moubray, author of Reliability Center
Maintenance, the evolution of maintenance since the 1930’s can
be traced through three generations. The distinction between these
generations depends up on basically three technical factors:
✓ Growing expectations of maintenance,
✓ Changing view on equipment failures, and
✓ Changing maintenance techniques
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Third Generation
▪Higher plant availability
▪Greater safety
▪Better product quality
▪No damage to the
Second Generation environment
▪ Longer equipment life
❖ Higher plant availability
▪ Greater cost
First Generation ❖ Longer equipment life
effectiveness
❑ Fix it when it broke ❖ Lower costs
Growing expectations of maintenance
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Changing view on equipment failures
Third Generation
Second Generation
First Generation
1940 1950 1960 1970 1980 1990 2000
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Changing maintenance techniques
Third Generation
▪ Condition monitoring
▪ Design for reliability and
maintainability
▪ Hazard studies
Second Generation
▪ Small fast computers
- Scheduled overhauls ▪ Failure modes and effects
First Generation - Systems for planning analysis
• Fix it when it and controlling work ▪ Expert systems
broke - Big, slow computers ▪ Multiskilling and team work
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First Generation
This covers the period up to the world war II. During this period:
– Industry was not highly mechanized
– Equipment Was not highly mechanized
– Downtime did not matter much
– Prevention of equipment failure did not have high priority
– Failures were corrected as they occur
As a result, there was not need for systematic maintenance beyond
cleaning, servicing and lubrication.
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 the equipment failures could and should be maintained came up
As a result, the concept of preventive maintenance and maintenance planning and
control systems grew up.
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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 has become central
✓ Greater expectations have lead to new research which in turn are leading to
new techniques
The Challenges of Maintenance
As can be observed from the trends of the evolution of maintenance,
higher plant reliability and availability, personnel safety and
environmental protection including cost effective methods are given
focal importance activities.
As a result of these demands, maintenance is increasing facing new
challenges.
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The challenges that modern maintenance managers face can be
summarized as follows:
To select the most appropriate maintenance techniques
To deal with each type of failure process appropriately
In order to fulfill the expectations of users
In the most cost-effective and sustainable mode
With active support of people involved
Maintenance Management
Maintenance is related to profitability through
✓ equipment output and equipment running cost;
✓ time taken for maintenance purposes
With increasing industrialization and complexity of machinery, the importance of
maintenance increases as downtime and costs related to downtime become increasingly
prohibitive.
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To understand maintenance and its various characteristic features, it is imperative to
know what an equipment life-cycle comprises and the factors at the various stages as
they relate to maintenance. The level of maintenance activity required and maintenance
management involved at the equipment operation stage is affected by factors at other
stages through which the equipment passes. These stages are briefly discussed below
indicating how maintenance is affected by the actions undertaken at the respective stages.
Design stage:
• The most important features of maintenance, particularly reliability and
maintainability should be considered properly in relation to performance of
equipment, capital and running costs right at the design stage. Good maintainability
and reliability characteristics are incorporated in the system at this stage.
Installation stage:
• Maintainability is an important factor to be considered during the installation, for it is
here that maintenance problems become clear.
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Commissioning stage:
• This is a stage of technical performance testing and also a stage of where
primary design faults are located and designed out.
• During commissioning, maintenance effectiveness can be analyzed and
changes can be affected in the system.
Operational stage:
• The operational stage is a stage of continued learning where maintenance
plays an important role.
• In this stage, mal-operation should be avoided and maintenance activities are
optimized so as to exploit the system reliability and maintainability
characteristics.
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During the operation period or useful life of an equipment proper
maintenance management can influence resource utilization and
profitability of an industrial plant. Maintenance management is the
direction and organization of resources in order to control the availability
and performance of an industrial plant to a specified level. Normally, to
meet the workload in a timely and cost effective manner, any maintenance
management is faced with a two-dimensional problem and these are
✓ Determination of size and nature of the maintenance work load, and
✓ Organization and control of resources i.e. men, spares and equipment
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Function of maintenance work
The maintenance department influences plant availability directly
through preventive and corrective maintenance tasks.
The most basic definition of availability is expressed by the equation
𝑇𝑜𝑝
Availability =
𝑇𝑜𝑝+𝑇𝑑𝑜𝑤𝑛
Where 𝑇𝑜𝑝 = Cumulative time of operation, up-time
𝑇𝑑𝑜𝑤𝑛 = Cumulative outage time, downtime
Downtime does not consist only of the time taken for repair but also
includes delays due to lack of resources and information.
Downtime = repair time + delays
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• Repair time is affected by management, system or equipment maintainability as
well as engineering techniques.
Mathematically, this can be stated as
Repair time = f (maintainability, management method, engineering techniques)
• Delays are influenced by organization of maintenance resources and flow of
information and this can be expressed as
Delays = f (organization of maintenance resources and information)
Plant availability is greatly influenced by reliability and maintainability.
o These characteristics are built in at the design stage and then after affect the
maintenance workload. Causes of low reliability or maintainability can only be
removed by engineering re-design which is not the responsibility of maintenance
department.
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....cont’d
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Classification of maintenance
• Depending on the nature of maintenance workload as related to time, maintenance is
broadly classified into two
– Preventive maintenance
– Corrective Maintenance
Preventive maintenance is the technique of minimizing untimely equipment
breakdown and /or an equipment’s condition falling below a required level of
acceptability.
Preventive maintenance calls for taking equipment off-line for repair at planned intervals
(time-based) or depending on the equipment condition (condition-based). Scheduled
maintenance is performed at regular intervals for the purpose of keeping the system in a
condition consistent with built-in levels of reliability, performance and safety.
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....cont’d
• The basic reasons for undertaking preventive
maintenance are the following.
✓Increased automation
✓Loss of profitability due to production delays
✓Just-in-time manufacturing policy
✓Production requirement for higher quality
✓Reduction in equipment redundancies
✓Reduced cost of maintenance
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....cont’d
• The last item, reduction in maintenance cost is achieved in
many different ways:
❖ Reduced production downtime resulting in fewer machine
breakdown
❖ Better prevention of equipment and increased useful life expectancy
which eliminates premature replacement of equipment/machinery
❖ Efficient use of maintenance labor achieved by working on of
schedule basis instead of crash basis repair breakdown
❖ Timely routine repairs resulting in fewer large scale repairs, etc
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....cont’d
• Care: regular care of normally operating
subsystems and components requires such
activities filling like cleaning, lubrication etc.
• Servicing: Servicing of subsystems and components
includes care along with other activities such as,
filling in of oil and fuel, readjustment, re-setting,
adjusting, checking without instruments.
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• Inspection: Inspection of subsystems and components comprises servicing
together with checking, testing, measuring, examining. The activities
carried out during inspection are Checking of function (comparison with
required data), and Gauging (use of measuring instruments).
• Repair: repair activities include replacement of damaged and destroyed parts or
those nearing wear-out, and reconditioning of components. Repair actions
normally require disassembling and assembling of components.
• The frequency of performing regular care, inspection and servicing to prevent
degradation of reliability depends on the characteristics of the components.
• Repair/replacement of components should be done by highly qualified
maintenance personnel to avoid maintenance-induced problems.
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Corrective Maintenance
• Corrective maintenance is defined as that which is
carried out when equipment fails or falls below
acceptable condition while in operation. Basically,
corrective maintenance is an emergency
maintenance which is carried out after breakdown,
thus it is a shutdown activity.
– off-schedule maintenance required by system in-service
failure or malfunction.
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Maintenance objectives, planning control
• The proper maintenance objective is the minimization of the sum of plant
unavailability and resource costs through the proper planning and control
of maintenance work. A unit is considered to be in one of the following
states:
– In production -------------------------------------- available
– Undergoing repairs----------------------------- unavailable
– Waiting for repair ------------ ----------------- unavailable
– Undergoing preventive maintenance ------ unavailable
• Maintenance objective is minimization of the resources and unavailability costs.
Unavailability cost = loss of in-service material and production loss while in repair
Or undergoing preventive maintenance
Resource cost = correct maintenance labour, preventive maintenance labour,
Maintenance equipment spares usage and holding costs
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An established maintenance organization and planning, needs to set-up a
control system to ensure that the organization is continually updated. This
control system performs three main interrelate functions: work control,
plant condition control and maintenance cost control. These three functions
are interrelated in that they are targeted at minimizing maintenance costs.
Work control
This is a function of the maintenance organization and its object is to match
men, spares and equipment to the maintenance workload. The function
includes
– Location of plant failure
– Determination of the necessary corrective action
– The setting of priorities
– Coordination and control of resources
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Plant condition control
This function is the required in order to achieve optimum plant performance in
the long term. The function of plant condition control is to:
– Identify the most important problems
– Diagnose causes
– Prescribe solutions
– In achieving this function the alternative actions available are:
– Modification of preventive maintenance policy
– Equipment re-design (especially, in the early period of an equipment life)
– Changes in production policy
Maintenance cost control
– The objective of maintenance control, as the name implies, is to minimize
the sum of costs related to maintenance activities. The functions of
maintenance cost control is:
– To identify high cost areas of plant
– To monitor the trend of maintenance effectiveness
– To provide information for maintenance decision making
– To facilitate maintenance budgeting
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Introduction to Machine Installation Objectives:
• Define concepts of machine installation and safeguarding
• Introduce requirements of foundation, Anchoring methods,
Leveling, Machine Alignment, and Isolation of Foundations
Machine: It is a device that takes some energy as input and
transforms it to another useful form of energy as output.
Machine Installation: It is the process of fixing and erecting the
machinery in an industry so that they can be put to use for
productive purposes.
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Why Machine installation is necessary?
It is the first step in the productive process of any newly
established plant.
Where to install machinery?
The installation of light machinery used for domestic use may not
require any expertise, where as the installation of the machinery
used in the industry need attention as the performance of the
machinery largely depend upon proper installation. How to install
machinery? The installation process may differ from machine to
machine and it is largely depend
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Factors to be considered before installing the machinery
the machine to be installed, this will include:
❑ Machine size and weights
❑ Any dynamic features of its operation
❑ Location including ground type, condition where optimal performance is required
❑ Vibration analysis of the machine
❑ Site conditions
Machine Foundations
The main purpose of machine foundations is to stabilize the machine as well as to
reduce the vibrations caused due to the operation of the machine. The foundation thus
positively influences machine vibration by reducing the amplitude of oscillation. The
first step in machine installation is to find out whether it is required to build a special
foundation for installation .
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