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BITSPilaniPilani Campus

ENGG ZC242

Maintenance & SafetyAnil Jindal

Department of Mechanical Engineering

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BITSPilaniPilani Campus

Introduction to Maintenance

SystemsChapter ! "ecture #2

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BITS Pilani, Pilani Campus

Maintenance Objectives!cope and "enefitsPolicies

Maintenance as "usiness Proposition

Maintenance Philosoph# $#pes of Maintenance !#stems

"earnin$ %'ecti(es

%

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Maintenance %'ecti(es

&

Operational' Ma(imum operating efficienc# of plant

' Ma(imum availabilit# of plant

' )igh *ualit# performance

' !afet#

' $o maintain a plant clean + good appearance

' $o e(tend Plant life to the last limit

' $o reduce environmental impact due to machiner# etc

' $o provide service that ill avert all brea-dons at all times at an# cost.

Cost' Minimi/e maintenance e(penditure and ma(imi/e profits

' $o provide activities ith in the limits of budgetar# control

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Maintenance Benefits

0

inancial

Organi/ational

$echnical )uman

Customer relations

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)inancia* Benefits

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E(tended Plant 3ife

4ninterrupted production

5mproved 6ualit# of production 7educed production dela#s

7educed cost of repairs

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%r$ani+ationa* Benefits

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Co9ordination beteen production and maintenance

Man poer planning

Planning of deliveries

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Technica* Benefits

:

5mproved e6uipment suitabilit#

"uild up of technical data

5mproved maintenance schedules 5mproved plant condition

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,uman considerations

Benefits

;

5ncreased !afet#

5mproved )ouse -eeping

3ess friction beteen relationships

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Customer re*ationship

Benefits

1 house -eeping

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Maintenance -o*icy

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!cope and limits of maintenance

$#pe and level of service e(pected

7esponsibilities to management Personal Practices

$rade union contracts

"udget and financial controls

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Primar# unctions' Maintenance of e(isting plant e6uipment

' Maintenance of e(isting plant buildings and grounds

' E6uipment inspection and lubrication

' 4tilities generation and distribution

' Alterations and ne installations

!econdar# unctions' !tore-eeping

' Plant protection

' ?aste disposal

' !alvage

' 5nsurance

' Other services

Maintenance )unctions

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$he maintenance costs continue to capture the attention

of senior management as the investment as reliabilit# in

assets become increasingl# greater.

5n some companies, maintenance cost is becoming a

larger percentage of total cost.

or e(ample, a compan# recentl# identified maintenance

cost as in e(cess of &< percent of their total cost of

conversion, representing significant scope for

improvement. )ence it is essential to run maintenance as business.

Maintenance as Business

-roposition

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!ome organi/ations have centrali/ed hich are responsible for allaspects of asset management.

$he responsibilities of these centrali/ed departments includeB

specif#ing, ac6uiring, installing, and commissioning ne plant,

managing spare parts, planning and control of maintenance s#stem

etc.

"ut in most companies engineering is separated from maintenance.

Engineering department loo-s for specification, ac6uisition and

deplo#ment of ne plant, hile the maintenance department loo-s for

all aspects of maintenance after the plant has been commissioned.

$he concept of business unit started to emerge about to decadesago.

The Business 0nit Concept

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Business 0nit Concept

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$he concept has sub9divided larger underta-ing into businessunits, usuall# centered on specific product or service

Maintenance department is often bro-en up and its personnel

allocated to the business units.

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)uge leap in automation in last to decades.

$he number of operators have shrun- and the machines

are ta-ing over.

5ncase of some s#stems there are no operators.

Computer programs drive these s#stems ith occasional

additional guidance from people in distant control room.

More machines rep*acin$ men means! more

maintenance acti(ities1

utomation

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!enior e(ecutives thin- that if it ere possible to reducee(penditure on operation, it should be possible to reduce

maintenance cost b# similar amount.

Companies have achieved an increase in production b#

replacing men b# machines and this increases the costof maintenance.

So decrease in operatin$ cost is accompanied y

increase in maintenance cost1

Maintenance manager should be aare of the folloingo !afe minimum to be spent on proactive maintenance

o Conse6uences of not spending enough on maintenance

Maintenance cost reduction

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Most people thin- of the maintenance function asB

o i(ing things that brea-.

o eeping things loo-ing good.

o eeping things from brea-ing.

"ut for a structured maintenance, the folloing 6uestions

have to be ansered

o 5s it that staff and suppl# are planned onl# to address brea-don

o ?hat is the cost of e6uipment dontime

o )o much time is re6uired for routine maintenance activities

o ?hether focus needs to be on activities to reduce brea-don or allo

things to brea- don

Maintenance -hi*osophy

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3ifferent Maintenance Systems

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Documents

ENGG ZC242-L2