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Program : MBA

Semester : IV

Subject Code : OM0015

Subject Name : Maintenance Management

Unit number : 1

Unit Title : Introduction, Needs and Importance of

Maintenance

Lecture Number : 1

Lecture Title : Introduction, Needs and Importance of

Maintenance

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Objectives

The objectives of this lecture are to:

• Discuss Maintenance Management

• Explain the Need and Importance of Maintenance

• Discuss the Types of Maintenance

• Describe the Organisational Objectives and Functions of Maintenance

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Unit-1 Introduction, Need and Importance of Maintenance Management

Introduction, Need and Importance of Maintenance Management

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Lecture Outline

• Introduction

• Maintenance Management

• Objectives

• Classifications

• Need and Importance

• Organisational Objectives

• Functions and Policies

• Capability Factors

• Widely Adopted Methods

• Summary

• Check Your Learning

• Activity

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Unit-1 Introduction, Need and Importance of Maintenance Management

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Introduction

• Maintenance is the fundamental requirement for keeping up

productive resources in good working condition throughout their

lifetime.

• Maintenance management is the systematic approach involved in

planning the maintenance activities to improve the overall efficiency

of the entire operating system.

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Unit-1 Introduction, Need and Importance of Maintenance Management

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Maintenance

The steps involved in maintenance are:

• To understand the current maintenance process

• To determine if the current process suits the task

• To list out process improvement actions

• To plan action in order to perform the required tasks

• To commit resources to execute the task as per the time frame

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Unit-1 Introduction, Need and Importance of Maintenance Management

C o n f i d e n t i a l

Objectives

The main objectives of maintenance management involve:

• Planning maintenance activities and evolving policies• Creating an organisational structure for the department• Organising maintenance resources• Directing execution of maintenance plan• Controlling the performance of maintenance activities• Defining processes for performing maintenance• Budgeting and controlling costs

Unit-1 Introduction, Need and Importance of Maintenance Management

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Classification

Maintenance process can be classified into five groups:

Unit-1 Introduction, Need and Importance of Maintenance Management

Group 1: Maintenance is carried out while the equipment is running.

Group 2: Maintenance is carried out on an idle machinery.

Group 3: Machine or equipment is taken out of the production for scheduled

maintenance.

Group 4: Equipment or machine has failed and is readily available for

maintenance.

Group 5: The equipment has failed but it is waiting for maintenance.

Maintenance

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Need and Importance

The factors that have created the need for maintenance management

include:

• Higher operating costs

• Environmental concerns

• Safety issues

• Warranty and liability factors

• Regulatory matters

• Ageing of plant

• Increased cost of replacement

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Unit-1 Introduction, Need and Importance of Maintenance Management

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Importance

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Unit-1 Introduction, Need and Importance of Maintenance Management

The implementation of maintenance management is inevitable

because of the following:

• Break down of machinery hinder the performance of the

production process

• Repair of machinery is expensive once it breaks down

• Quality of the product suffers if machines malfunction

• Workers become idle during breakdown and repair time

• Machine failure may lead to accidents in some cases

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Organisational Objectives

The organisational objectives achieved by a good maintenance

management are as follows:

• Reduction in the loss of productive time• Minimum repair time and cost• Optimum use of resources and facilities• Extend the life of costly capital assets• Provide effective and efficient use of maintenance personnel• Improve the quality of productive assets

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Unit-1 Introduction, Need and Importance of Maintenance Management

Functions

The functions of the maintenance management include:

• Maintenance of buildings and services

• Inspection and lubrication of machinery and equipments

• Maintenance of utilities and distribution

• Installations of new equipments

• Alterations to the assets for ease of work

• Maintenance of existing plant and machinery

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Highlights of a good maintenance policy involve:

• Encouraging the right maintenance practices

• Providing the backup for machines evolved in critical operations

• Replacing parts before they are expected to fail

• Ensuring proper training of the machine operators

• Designing machines for maintainability and quick repair

provisions

• Enhancing staff capability factor and thus building flexibility for

cross functional activities

• Stocking adequate spare parts to reduce downtime

• Improving process for reduced wear and stress on machines

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Unit-1 Introduction, Need and Importance of Maintenance Management

Maintenance Policies

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Factors enhancing the capability and effectiveness of maintenance

include:

• Work management policy

• Well structured training strategy

• Optimal resource management

• Quality assurance in all activities

• Outsourcing plan and procedures

• Commitment of the maintenance personnel

• Supervisory role

• Process improvement and measurement

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Unit-1 Introduction, Need and Importance of Maintenance Management

Capability Factors

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Widely adopted maintenance techniques are:

• Routine maintenance• Planned maintenance • Break down maintenance• Corrective maintenance• Remedial maintenance • Preventive maintenance• Predictive maintenance• Condition based maintenance• Total productivity maintenance

Widely Adopted Techniques

Unit-1 Introduction, Need and Importance of Maintenance Management

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Summary

• Maintenance management is concerned with the direction and

pooling of all internal resources to control the availability and

performance of the equipments and machineries at expected levels.

• It is very essential for any organisation to emphasise and establish an

efficient and effective maintenance department.

• Maintenance management has to define and establish sound

maintenance practices and processes.

• Maintenance is categorised as preventive, predictive, and remedial.

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Check Your Learning

1. Name five maintenance techniques

Ans. The five maintenance techniques are:

Routine Maintenance, Planned Maintenance, Preventive Maintenance,

Predictive Maintenance and Condition Based Maintenance

2. State whether true or false:

i) Routine Maintenance is a cyclic operation recurring periodically

Ans. True – Routine Maintenance is a procedure followed regularly

ii) Repairing machinery is inexpensive once it breaks down

Ans. False – It gets very expensive to get the machine repaired once it

reaches the breakdown stage. It also affects the production and labour

hours.

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Unit-1 Introduction, Need and Importance of Maintenance Management

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Activity

List out the main areas where condition based maintenance

can be implemented.

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Unit-1 Introduction, Need and Importance of Maintenance Management