Download - MEM 1 Objectives Types [Compatibility Mode]
• Egyptian Tomb : Ra-En-Ka 2600-1700BC
Sledge was used to transport monument
Arivoli.N Asst Prof DFT NIFT Bangalore
2Tuesday, February 12, 2013
Maintenance
• Maintenance is the routine and recurring
process of keeping a particular machine or
asset in its normal operating condition so that
it can deliver its expected performance or it can deliver its expected performance or
service without causing any loss of time on
account of accidental damage or breakdown(RCM)
Arivoli.N Asst Prof DFT NIFT Bangalore
3Tuesday, February 12, 2013
If not maintained …
• A poorly maintained Steam Boiler may cause a
serious accident
• Failure of Rope of a winder used in mines
• Costly Down Times• Costly Down Times
• Production Delays- Lead Time extension
Arivoli.N Asst Prof DFT NIFT Bangalore
4Tuesday, February 12, 2013
• Maintenance Engineering consists of knowledge and skills aimed at reducing the cost of maintenance and increase system productivity and safety.system productivity and safety.
Arivoli.N Asst Prof DFT NIFT Bangalore
5Tuesday, February 12, 2013
• Maintenance Engineering is the discipline and
profession of applying Engineering concepts to
the optimization of equipment, procedures,
and departmental budgets to achieve better
Reliability,
Availability and
Maintainability
of equipment. (RCM)
Arivoli.N Asst Prof DFT NIFT Bangalore
6Tuesday, February 12, 2013
• A Maintenance Engineer shall possess
significant knowledge of Statistics, Probability
and Logistics, and additionally in the
fundamentals of the operation of the fundamentals of the operation of the
equipment and machinery he or she is
responsible for.
Arivoli.N Asst Prof DFT NIFT Bangalore
7Tuesday, February 12, 2013
Maintenance Objectives(SKS)
• To maintain Plant & equipment at its
maximum operating efficiency , ensuring
operational safety and reducing Down time
• To safe guard investments by minimizing rate • To safe guard investments by minimizing rate
of deterioration
• To help Mgmnt in taking decisions on
replacements or new investments
Arivoli.N Asst Prof DFT NIFT Bangalore
8Tuesday, February 12, 2013
Maintenance Objectives
• To actively participate in specification
preparation, Vendor /Equipment selection,
Rating, Import Substitution, E &C
• Standardization of Spares and consumables as
per National or International Stdsper National or International Stds
• Running of Centralized services like Steam
Generation, Water Supply, Air Supply and Fuel
Supply etc
• Repair and Reconditioning
Arivoli.N Asst Prof DFT NIFT Bangalore
9Tuesday, February 12, 2013
Maintenance Objectives (RCM)
• Most Important Objective: Maximization of
Improving Productivity thru
Maximum Availability at
Optimum Cost
• Most Important Objective: Maximization of
the availability of equipment or Facilities
• To establish Safe working conditions both for
Operating and maintenance personnel
Arivoli.N Asst Prof DFT NIFT Bangalore
10Tuesday, February 12, 2013
• Elimination of future defects
• Prevent breakdown during operation
• Ensure safety during operation
• Maximize operational efficiency
• Reduce idle hours due to component
malfunctioningmalfunctioning
• Enhance Performance level
Arivoli.N Asst Prof DFT NIFT Bangalore
11Tuesday, February 12, 2013
Break Down Analysis
1 Breakdown
Arivoli.N Asst Prof DFT NIFT Bangalore
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10
100Poor Practices
Faults
Tuesday, February 12, 2013
Maintenance Approaches
Planned Mntc Break Down Mntc
Arivoli.N Asst Prof DFT NIFT Bangalore
13
Preventive
Mntc
Predictive
Mntc
Corrective
MntcCBM RCM
Tuesday, February 12, 2013
Scheduled
Maintenance
Annual
Shut
Down
MRO
AMC
MO
TPM
Systems approach to Maintenance
• Identification of Mntc needs
• Analyzing and Prioritizing the requirements
• Determining the Functional procedures for
Maintenance Task Selection, Work Planning and
Scheduling, Work Order ProcessingScheduling, Work Order Processing
• Outlining a Reporting and Controlling Procedures
• Development of Supporting Facilities and
Infrastructure
• Determining Cost Accounting Procedures
• Adopting a Policy for Training and Quality Assurance
Tuesday, February 12, 2013Arivoli.N Asst Prof DFT NIFT
Bangalore14
Breakdown Maintenance
• No mntc work is done until an equipment fails
or becomes inoperative
• Equipment is allowed to run till it stops
working and no efforts made in advance to working and no efforts made in advance to
prevent the failure of parts
• During the repair time , no proper care is
taken to know the real cause of the
breakdown, which may lead to similar
frequent failures
Arivoli.N Asst Prof DFT NIFT Bangalore
15Tuesday, February 12, 2013
Planned Maintenance
• An organized type of maintenance
• When
• What • What
• by Whom
Equipment specific : nature of equipment and its
working conditions
Preventive, Predictive, Corrective, CBM, RCM
Arivoli.N Asst Prof DFT NIFT Bangalore
16Tuesday, February 12, 2013
Scheduled Maintenance• Actual Maintenance Programme is scheduled
in consultation with the Production
Department
• Predetermined Mntc activity so as to utilize
idle time of the Machine effectivelyidle time of the Machine effectively
• Effective utilization of Manpower
• Enhances Availability and Reliability
Tuesday, February 12, 2013Arivoli.N Asst Prof DFT NIFT
Bangalore17
Corrective Mntc
• Focussed on regular planned Tasks that will maintain all critical machinery and system in optimum operating conditions
• All repairs are well planned and implemented • All repairs are well planned and implemented by properly trained people
• Cycle cost of critical equipment is considered
• Objectives:Eliminate B/Ds, unnessary repairs & deviations from Optimum
operating Cond, optimize all critical plant systems
Arivoli.N Asst Prof DFT NIFT Bangalore
18Tuesday, February 12, 2013
Preventive Mntc
• Is the utilization of planned and coordinated
inspections, adjustments and minor repairs in
maintaining plant
• It is designed for day-to day mntc like • It is designed for day-to day mntc like
cleaning, inspection, lubrication, retightening
to retain healthy condition of equipments
• Routine Attention, Routine Examination and
Preventive Replacements of Minor parts
Arivoli.N Asst Prof DFT NIFT Bangalore
19Tuesday, February 12, 2013
Predictive Maintenance
• Regular Evaluation of the actual operating conditions
of Plant Equipment and production systems
• Predicting the failures based on the past data or from • Predicting the failures based on the past data or from
the OEM supplier and replacing if required
• Provides timely factual data that states the operating
conditions of critical production systems and
effectiveness of critical plant function such as
purchasing, Engineering and productionArivoli.N Asst Prof DFT NIFT
Bangalore20Tuesday, February 12, 2013
CBM Condition Based Mntc
• Carried out in response to a significant
deterioration in a unit or system as indicated
by a change in a monitored parameter
• Most suited for high capital cost equipment • Most suited for high capital cost equipment
and complex replaceable items
• Vibration, temperature, noise
• Failure Data necessary
• Condition monitoring: Online & Offline
Arivoli.N Asst Prof DFT NIFT Bangalore
21Tuesday, February 12, 2013
RCM Reliability Centered Mntc
• To identify the mntc requirmnts of equipmnt
• Establishes Functional Requirements and the
desired performce Stds of Equipmnt and then
relates to design and inherent reliability relates to design and inherent reliability
parameters of the m/c
FMEA
FTA
Arivoli.N Asst Prof DFT NIFT Bangalore
22Tuesday, February 12, 2013
Computerized Maintenance Management
System CMMS
• A computerized maintenance management system will contain a number of integrated
programs or modules to improve the efficiency and effectiveness of the mntc func.efficiency and effectiveness of the mntc func.
• Preventive maintenance
• Asset register
• Maintenance stores system
• Purchasing
• Work order planning and control
• Plant history and analysis
Arivoli.N Asst Prof DFT NIFT Bangalore
23Tuesday, February 12, 2013
TPM
Total Productive Maintenance
Introduced in GE, USA 1960 Productive Mntc
TPM- Nippon Denso Co. Japan, 1971TPM- Nippon Denso Co. Japan, 1971
Nationalised in 1983 by JIPM
Japanese Inst of Plant Maintenance
Arivoli.N Asst Prof DFT NIFT Bangalore
24Tuesday, February 12, 2013
• Terotechnolgy- UK 1970s
• 5 Zero Concept
“0” Break Down
“0” Fault
“0” Delays
“0” StockOuts“0” StockOuts
“0” Paperwork
• RBM/RCM Reliability Centered Mntc
• Creative Maintenance
Arivoli.N Asst Prof DFT NIFT Bangalore
25Tuesday, February 12, 2013
Organzation struc of a Garment indWhere does Mntc Dept stand?
Arivoli.N Asst Prof DFT NIFT Bangalore
26Tuesday, February 12, 2013
Admin Structure of MNTC Dept
Senior Mntc Engr
Arivoli.N Asst Prof DFT NIFT Bangalore
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Work Planning
Engineer
Mntc Engr
Mech, ElectMntc
Superintendent
Foreman
Foreman 1
Foreman 2
Preventive Mntc
Foreman
Planning
Foreman
Tuesday, February 12, 2013
Maintenance
Superintendant
Engineering
Assistant
Facilities
Foreman
Foreman
Shops
Foreman
Planng &Foremn
Engg
Field
ForemanForemanShops
Mntc
Planng &
MntcEngg Foreman
Steam
Power
Water
Air
Mntc
Repair
Lurication
Constructn
Wrk order
Planng &
Estmn
Schedulg
Backlog ctrl
Performnce
Reports
Engg
Design
Buildngs
Yards
Fire
protctn
Waste
Disposal
Arivoli.N Asst Prof DFT NIFT Bangalore
28Tuesday, February 12, 2013
Challenges in Maintenance
• Rapid growth of Technology- Obsolescence
• Advent of New diagnostic tools,rapid repair systems
• Requirement of keeping both old and modern
machines
• Coping up with different tools- Lean, Kaizen, JIT,
Quality circles,5S,TPS,TPM
• EMS
• OHSHAS
• Effective R&D
• MIMS, Expert Systems
• Cost Control Tuesday, February 12, 2013
Arivoli.N Asst Prof DFT NIFT Bangalore
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Tradeoff Between Repairs and PMAnnual CosAnnual CosAnnual CosAnnual CosAnnual CosAnnual CosAnnual CosAnnual Cost t
Minimum TotalMinimum TotalMaintenance CostMaintenance Cost
Total Total MaintenanceMaintenance
CostsCosts
Arivoli.N Asst Prof DFT NIFT Bangalore
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Degree of Preventive MaintenanceDegree of Preventive MaintenanceDegree of Preventive MaintenanceDegree of Preventive MaintenanceDegree of Preventive MaintenanceDegree of Preventive MaintenanceDegree of Preventive MaintenanceDegree of Preventive Maintenance
PreventivePreventiveMaintenanceMaintenance
CostCost
BreakdownBreakdownand Repairand Repair
CostCost
CostsCostsMinimumMinimum
Level ofLevel of
PreventivePreventive
MaintenanceMaintenance
Tuesday, February 12, 2013
Responsibilities of Mntc dept• Personnel Management- Skill Inventory-HRP
• Synchronize with Production Dept- Targets
• Job Distribution and Supervision
• Feedback and Control
• Finance Mgmt-Budgeting Mntc Funds-Proper • Finance Mgmt-Budgeting Mntc Funds-Proper
Allocation
• Inventory Management-ABC analysis-Spareparts
Classification
• Maintaining Data- Manuals, Repair & DT History,
Updating of Mntc Activities
• Preparing Maintenance Checklists and identifying
Mntc Check PointsTuesday, February 12, 2013Arivoli.N Asst Prof DFT NIFT
Bangalore31