Maintanance Mgm Ppt

8/10/2019 Maintanance Mgm Ppt

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DR. MAHADEO GHADGE



What is Maintenance

• The activity carried out to prevent theoccurrence of failure and activitycarried out after failure to rectify the

defect is called maintenance.



Why Maintenance Required

• Plant and machines in anyorganisation is expected to runcontinuously without any interruption

during the production period.• Interruptions are frequently felt on

account of machine break downs dueto failures of machine parts /components.

• There is always some loss ofproduction on account of machine

failure.



4

C USES OF F ILURE OF M CHINES



Down Time

• The duration by which any machine goesout of production due to break down iscalled down time.

• The down time is the total time taken on

account of maintenance to rectify the fault.• The total time taken on account of

maintenance involves the time actuallyspent by the respective maintenance team

to correct the fault and waiting time forwant of spares required for rectify thedefect.

• Down time = Repair time + waiting time



Waiting Time

• The waiting time is the mostunproductive elements of total downtime . The reason for waiting time

could be :-

• Want of spares

• Want of crew members

• Lack of communication.

• Lack of proper supervision



Mean Time Between Failure( MTBF)

• This is the average time a machinecan operate without the occurrence ofany failure.

• MTBF indicates the operationalreliability of the machine. Higher thevalue of MTBF, higher will be the

operational reliability of the machinebecause of lesser number of failures.



Mean Time Between Failure( MTBF)

• To improve the operational reliability ,the number of failures should bereduced. Failures can be reduced if

the machines are maintained properlywith adequate care and attention.

• Failures can reduce by better

maintenance.



OBJECTIVES OF PP

Continuous increase in the production through

improved overhauling of machines in a plantat scheduled intervals.

Eliminating any risk of accidents in the plant

that might be cause of a machine breakdown.Proper maintenance of machines & their parts

to prevent & decrease the wear & tear of

machines & their parts.Through examination of the machines against

their productivity & accuracy level.

Minimizing plant shut down time.

OBJECTIVES OF MAINTENANCE



Maintenance

Corrective Preventive

Unplanned Planned

Break Down Correct/Rectify

Faults

Indirect Direct

Conditioning

MonitoringCleaning

Lubricating

Replacement

Overhauling

Failure Reports



PREVENTIVE MAINTENANCE• Machines are checked much in advance of any kind of

failures.

• Checklists are developed for each equipment or machineso that machine parts are checked for any incipientproblems.

• Once the problem is identified in advance, the required

corrective action is taken before the machine stopsfunctioning.

• Different behavior of various machine parts encounterdifferent problems at different frequencies.

• Some parts should be checked in each shift; others maybe checked once a day, a month, in three months, in six



CORRECTIVE MAINTENANCE

•

During preventive maintenance checks, certainproblems are noticed about the condition of themachine. The machine may be operating in a conditionthat may cause damage to the machine if continued tooperate. Therefore the machine is to be stopped with

out delay to correct the situation.• The corrective action taken after the checks under

preventive maintenance is termed as correctivemaintenance.

• Similarly, condition-monitoring checks may reveal thatthe machine has lots of vibrations.

• The steps for correcting the situation are termed ascorrective maintenance.



BREAKDOWN MAINTENANCE

• The sudden stoppage of a machine due tosome failure or problem is termed asbreakdown of the machine.

• In some organizations, machines are attendedonly when the machine has stoppedfunctioning.

• The maintenance carried out in this manner iscalled breakdown maintenance.

• In breakdown maintenance, repair andcorrective action is taken up when the problemhas actually cropped up.



Inspection maintenance Lubrication Maintenance

Cleaning maintenance

Record Maintenance Spare part maintenance

Service maintenance

Emergency maintenance

Maintenance training



The worn out or deteriorated machine part The machine part with corrosion (rust)

Loosely held nut or bold in machine

Improper alignment Defect in machine due to overheating

As soon as defects are identified , the

corrective action should be taken Inspection can be internal and external



Proper & regular lubrication help in reducingrate of wearing and tearing of machine. Toensure good lubrication following activitiesare often required

Identifying right part

Cleaning of oil tank

Replacing

Lubricating Scheduling the frequency of lubrication



Cleaning is done to remove unwanted thingsor dust witch affect badly performance ofmachine or tools.

Cleaning of transformer or resistor

Electrical fuses

Filters.

Motor Fan blades

Oil tank



Manufacturers instruction manual Drawing of parts

Spare part manual

Circuit diagram Machine detail

Machine record

Documents

Maintanance Mgm Ppt