mem 1 objectives types [compatibility mode]

Maintenance Engineering

• 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)



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



• Maintenance Engineering consists of knowledge and skills aimed at reducing the cost of maintenance and increase system productivity and safety.system productivity and safety.



• 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)



• 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.



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



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



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



• 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



Break Down Analysis

1 Breakdown


12

10

100Poor Practices

Faults

Tuesday, February 12, 2013

Maintenance Approaches

Planned Mntc Break Down Mntc


13

Preventive

Mntc

Predictive

Mntc

Corrective

MntcCBM RCM


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



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



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



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



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



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



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



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



• 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



Organzation struc of a Garment indWhere does Mntc Dept stand?



Admin Structure of MNTC Dept

Senior Mntc Engr


27

Work Planning

Engineer

Mntc Engr

Mech, ElectMntc

Superintendent

Foreman

Foreman 1

Foreman 2

Preventive Mntc

Foreman

Planning

Foreman


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



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


29

Tradeoff Between Repairs and PMAnnual CosAnnual CosAnnual CosAnnual CosAnnual CosAnnual CosAnnual CosAnnual Cost t

Minimum TotalMinimum TotalMaintenance CostMaintenance Cost

Total Total MaintenanceMaintenance

CostsCosts


30

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


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

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