L - 1, Maintenance Fundamentals

8/8/2019 L - 1, Maintenance Fundamentals

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Session 1

Maintenance Management



What is Maintenance?

Busy in fire fighting breakdowns rather

than preventing/eliminating the same.



A maintenance system of today includes

aspects as follows

1. Pr otecting the buildings, str uctur es and plants

2. Incr easing equipment availability and r educing

downtimes; also helping in incr ease utilization of

equipments

3. Contr olling and dir ecting labour for ces.

4. Economy in maintenance depar tment.



5. Maximizing utilization of available r esour ces.

6. Ensur ing safety of installations and also

r educing envir onmental pollution.

7. R ecor ding expenditur e and costing of

individual jobs and of depar tment/section.

8. Pr epar ing maintenance budgets.



9.Pr eventing waste of tools, spar es and other

mater ials.

10.Emphasis on waste r ecover y.

11.Impr oving technical communications.

12.Measur ing plant per for mance as a guide for

futur e actions.13.Tr aining of maintenance per sonnel on r elated

topics.



M aintenance Objectives

( i) To maintain plant and equipments at its maximum

oper ating efficiency, ensur ing oper ational safety

and r educing downtime.

( ii) To safeguar d investments by minimizing r ate of

deter ior ation and achieving this at optimum cost

thr ough budgeting and contr ol.

The maintenance objectives of a big industrial plant



( iii) To help management in taking decisions on

r eplacements or new investments and actively

par ticipate in specification pr epar ation,

equipment selection, its er ection and

commissioning etc.

( iv) Development of r esour ces for equipments and

spar es and pr oviding technical help for

Vendor's / equipment supplier's selection /

r ating and impor t substitution.



( v) Help in implementation of suitable pr ocedur es

for pr ocur ement, stor age and consumption of

spar es, tools and consumables etc.

( vi) Standar dization of spar es and consumables in

confor mity with plant, national and

inter national standar ds and help in adoption of

these standar ds by all user s in the plant. Also

help in var iety r eduction and inventor y contr ol.



( vii) R unning of centr alized ser vices like Steam

Gener ation, water supply, air supply and fuel

supply etc.

( viii) R unning of Captive Wor kshops for r epair and

r econditioning and also making some new

spar es.

( ix) Help in tr aining and development of skilled

wor kmen and executives.



Maintenance is an age-old function which

developed and pr ogr essed, knowingly or

unknowingly, along with the oper ation of

equipments. In ear ly ages, maintenance was,

pr obably, not a separ ate identity but the job of

maintenance was consider ed as par t and

par cel of-oper ator's job. This was possible

because of simplicity and openness of

machines and equipments.



In sewing machine, tailor used to lubr icate the

machine, thus, even the lubr ication job, which is

basically a maintenance job, was done by the

same per sonnel without giving the job a separ ate

identity. However , with the gr owth of

industr ialisation, the complexity of the machines

(mechanical, electr ical and electr onics together)

incr eased and the machines became less simple

and less open.



This star ted cr eating pr oblems for the oper ating

per sonnel and the concept of maintenance as asepar ate discipline and separ ate identity star ted.

Maintenance Pr evention (MP) was pr obably fir st

known in 1960s f r om a factor y Magazine in

United States and that said that Maintenance

Pr evention (MP) meant design, manufactur e or

pur chase of equipment which is f r ee f r om

maintenance.



Inflated and incr eased down time cost called for the

well managed maintenance pr ogr ams, to enhance

the life of existing equipments and components,

became the essential aspects of all management

str ategies.



It consists of specialists hence is a

knowledge house of the or ganization. The

specialization is pr edominantly achieved

thr ough hands-on exper ience over a per iod

of year s. Most of such specialists ar e

pr actice or iented and had limited academic

exposur e.



'Maintenance can be defined as a set of

activities that ensur e any physical asset

to continue to fulfill its intended

functions to the standar d of

per for mance desir ed by the user'



The activities in maintenance

commences r ight f r om design of the

equipment and culminates in

scr apping it, which means

maintenance is associated with

ever y par t of the equipment's entir e

lifecycle.



Maintenance doesn't limit its scope

to machiner ies as commonly

misunder stood, but includes land &

buildings, auxiliar y equipments,

safety equipments and office

equipments. In shor t maintenance

encompasses all the physical assets



The r ight maintenance is the one that

will ensur e per for mance of equipment

with highest possible efficiency

desir ed by the user



The efficiency level is decided by the

user because it is connected to the cost.

Efficiency doesn't come f r ee. Ever yinitiative demands cer tain cost or

compr omise and the user has to

balance it for an over all benefit



Maintenance Engineer ing/Maintenance

Management is the most impor tant

component of Plant Engineer ing and

Plant Engineer ing is pr obably the

biggest for ce to incr ease pr oductivity .



'Maintenance is an investment that

buys / gives mor e pr oduction time.

(example health of a per son)



Also we cannot cope up with today's jobs and

pr oblems with yester day's tools and techniques.

We have to use tools and techniques of today,

compatible with today's pr oblems and also with

the anticipated pr oblems of tomorr ow (near

futur e). Educational and r esear ch institutionsshould cooper ate with industr ies to ease out the

pr oblems.



If all these ar e not taken car e of, a

maintenance man would be so busy in

committing suicides that he would

har dly have any time to live i.e., he

would be busy in fir e fighting

br eakdowns r ather than pr eventing/

eliminating the same.



Q1.What is Maintenance ? State differ ent aspects

of Maintenance In today¶s wor ldQ2.What ar e differ ent Maintenance objectives

Q3.Why is it impor tant to know the stage of

pr oduct life cycle in which an equipment is in

the context of Maintenance

Q4.What is the r ole of Maintenance in

Manufactur ing?

Q5.How Maintenance per sonnel ar e r esponsiblefor pr ofit making and efficient r unning of

business in any or ganization?

Documents

L - 1, Maintenance Fundamentals