1. 4/11/2013Maintenance Management Why? Breakdown of one piece of equipment or component canhinder the performance of the entire production process,resulting in delays. Repairing a machine can be much more expensive once it Maintenance Management breaks down. Malfunctioning equipment may affect the quality ofproduct. Presented By: Scrap due to such equipment increases the unit productionAnupam Kumarcost. Reader During machine breakdown, the workers become idleresulting in higher unit cost of the product.SMS Varanasi Machine failure can even lead to accident in some cases. Objectives of Maintenance Maintenance Management Management Maintenance Management is planning, Maximize the availability of firms assets for productionpurposes. organizing and controlling of maintenance Preserve the value of the firms machinery and equipment activities such that the overall maintenance by reducing the rate of deterioration. To anticipate and prevent machine failure and breakdowns. cost is minimized. Improve the quality of products and increase the firms It strives to maintain optimum equipment productivity. Use maintenance personnel and equipment efficiently. conditions in order to prevent unexpected Minimize repair cost and repair time. breakdowns, speed losses and quality defects Minimize or totally eliminate accidents by regular arising from process activities. inspection and repairs. Efficient use of maintenance personnels.Scope of Maintenance ManagementPrimary Maintenance Functions All segments of the plant including the building, Maintenance of exiting plant, equipment, machinery, equipment, plant, tools, cranes, jigs & buildings, land, etc. fixtures, heating and air-conditioning Equipment inspection and lubrication equipments, generators, waste disposal systems, washrooms, dispensaries, etc need maintenance. Utilities generation and distribution Maintenance management can broadly be Alterations to existing equipment and building categorized into 2 functions: New installation of equipment & buildings Primary Function Secondary Functions Copyright 2013 Anupam Kumar1

2. 4/11/2013Secondary Maintenance FunctionsBenefits of Maintenance Management Store keeping (keeping stock of spare parts, etc.) The production capacity of the facility remains unaffected due to well maintained machines and thus Plant protection including fire protectionlesser breakdowns. Waste disposal Production cost can be kept minimum. Salvage Quality of products and services can be maintained Insurance administration (against fire, theft, etc.)due to reduced variation in output Janitorial Services Increased safety of the workers due to reduction in accidents. Property Accouting Delivery schedule of the customers can be maintained. Pollution and noise control Life of facilities and equipment increases. Any other service delegated to maintenance by plant management. Objectives of Breakdown Types of MaintenanceMaintenance There are basically two types of maintenance: To get the equipment back into operation as Breakdown Maintenance quickly as possible. It is a reactive approach in which repairs and replacement ofparts are performed only when the breakdown occurs. To control the cost of repair crews Preventive Maintenance To control the cost of operation of repair It is a periodic activity in which the time of maintenance canbe scheduled shops. either according to a calendar dependant upon thepredetermined number of operating hours of different To control the investment in replacementequipmentspare parts or on the basis of inspection of the equipment to find itsstate and need for maintenance. To perform appropriate amount of repair at each malfunction.Advantages of Preventive Preventive Maintenance Maintenance Preventive Maintenance involves Increase in life of machines & equipments by Proper design and installation of equipment reduction of wear & tear Periodic inspection of plant and machinery to Reduction in frequency of breakdowns. prevent break-downs before they occur. Improvement in productivity due to lesser machine Repetitive servicing, upkeep and overhaul ofdown-time and consequent loss of production. equipment. High reliability of production systems due to lesser Adequate lubrication, cleaning and painting ofbreakdown and repairs building and equipments Higher worker safety while using the plant and equipment. Its aim is to minimize the possibility of unanticipated break-downs. Copyright 2013 Anupam Kumar2 3. 4/11/2013Advantages of Preventive Limitation of Preventive MaintenanceMaintenance Planned shutdowns and start-ups of plant and More expensive in short term and during the equipment possible.initial stages of introduction of preventive Lesser requirement of stand-by machines due to maintenance program. lesser break-downs. Inspection of plant, equipment and machinery Minimum work-in-progress inventory due to reducedwill have to be carefully planned and production hold ups due to equipment breakdowns.implemented and improved over a period of Lesser rejection and better quality controltime. Less serious consequences of break-down and lesser break-down maintenance costs. Copyright 2013 Anupam Kumar 3