Maintenance management

Contents
Concept Importance Objectives Types

of maintenance Total Productive maintenance(TPM)

Concept
Two categories of maintenance activities in a firm are : i. Maintaining buildings, parking lots, lawns, fences, services and utilities.
ii.

Maintaining equipments, machinery, material handling equipments, transport vehicles, tools, test instruments, office equipments, etc.

 Maintenance:

It is the function of production management that is concerned with the day-to-day problem of keeping the physical plant in good operating condition. Management: It is concerned with the direction and organization of resources in order to control the availability and performance of the industrial plants to some specified level.

Maintenance

It involves maintenance planning, maintenance scheduling, execution of maintenance activities, and controlling costs of maintenance.

Maintenance covers two broad categories of functions : Primary functions Secondary functions

Primary functions
Maintenance

of existing plant and equipments. Maintenance of existing plant building and grounds. Equipment inspection and lubrication Utilities generation and distribution. Alternatives to existing equipments and buildings. New installations of equipments and buildings.

Secondary functions
Storekeeping Plant

protection including fire protection Waste disposal Salvage Insurance administration Janitorial services Property accounting Pollution and noise abatement or control Any other service delegated to maintenance by plant management

Importance of maintenance management

Equipments

must be kept in reliable condition without costly work stoppage and down time due to repairs if the company is to remain productive and competitive. Quality assurance Market share improvement Cost control Equipment failure will be disastrous for such companies. They need proper maintenance to maintain equipment in good condition.

Impact of Poor maintenance

Production

capacity costs

Production

Product

and service quality or Customer safety satisfaction

Employee

Customer

objectives
1. 2. 3. 4. 5. 6. 7. 8.

Minimizing the loss of productive time because of equipment failure(i.e. minimizing idle time of equipment due to break down). Minimizing the repair time and repair cost. Minimizing the loss due to production stoppages Efficient use of maintenance personnel and equipments Prolonging the life of capital assets by minimizing the rate of wear and tear To keep all productive assets in good working condition. To maximize efficiency and economy in production through optimum use of facilities. To minimize accidents through regular inspection and repair of safety devices

9. To minimize the total maintenance cost which includes the cost of repair, cost of preventive maintenance and inventory carrying costs due to spare parts inventory 10. To improve the quality of products and to improve productivity.

Types of Maintenance
1.

Break down maintenance or Corrective maintenance Preventive maintenance Predictive maintenance Routine maintenance Planned Maintenance

2. 3. 4. 5.

Break down maintenance or Corrective maintenance

As

the name suggests, corrective maintenance occurs when there is a work stoppage because of machine breakdown or fail and must be repaired on urgent basis.

Corrective maintenance seeks to achieve the following objectives

To get equipment back into operation as quickly as possible to minimize interruption to production. To control the cost of repairing. To control the investment in replacement spare parts that are used when machines are repaired. To perform the a appropriate amount of repairs at each malfunction.

Preventive maintenance
Preventive

maintenance is undertaken before the need arises(i.e. machine or equipments fail) and aims to minimize the possibility of unanticipated production interruptions or major breakdowns. It consists of Proper design and installation equipments Periodic inspection of plant and equipment Repetitive servicing, upkeep and overhaul of equipment Adequate lubrication, cleaning and painting of buildings and equipment.

A well-conceived preventive maintenance programme should contain the following features:

1. 2. 3. 4. 5. 6. 7.

Proper identification of all items to be included in the programme. Adequate records covering volume of work, cost and so forth. Inspection on define schedule Use of checklist by inspectors Well qualified inspectors Use of repair budgets for major items of equipment Administrative procedures that provide necessary fulfillment and follow-up on programme.

1. Job identification or preparation of facility register 2. Preventive maintenance schedule 3. Machine history record 9. Corrective and control action

8. maintenance request

4. Job specification

7. Maintenance action(inspection report) 6. Preventive maintenance schedule(weekly, monthly)

5. Preventive maintenance Programme

Benefits of Preventive maintenance

Greater

safety for workers Decreased production downtime Fewer large scale and repetitive repairs Less cost for simple repairs made before breakdown Less standby equipment required Better spare parts control Lower unit cost of manufacturer

Predictive maintenance
It

is modern approach to preventive maintenance using sensitive instruments to predict anticipated failure of machines and equipments

Routine maintenance
This

includes activities such as periodic inspection, cleaning, lubrication and repair of equipments after their service life.

1.

2.

Running Maintenance Maintenance work is carried out while the equipment is in the operating condition. e.g. greasing or lubricating the bearing while machine is running Shut down maintenance Maintenance work is carried out while the equipment is out of service. e.g. Repairing boiler tubes of a boiler.

Planned Maintenance
Here,

maintenance activities are carried out according to a predetermined schedule. is also called as scheduled maintenance or productive maintenance. aims to reduce machine stoppage due to sudden breakdowns necessitating emergency maintenance.

It

It