Girish Kant
Department of Mechanical Engineering
BITS Pilani
Pilani Campus
Learning Objectives
Financial, Human and Physical asset management
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in
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Conventional Systems of
Ordering Spare Parts and Materials
Inventory control theories attempt to determine those
procedures, which will minimize the costs of:
i.
order quantity)
iii. Holding
stock
(interest
on
capital,
insurance,
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Underlying Assumptions
The demand for the item is known
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F = holding cost factor, the factor of the purchase cost that is used
as the holding cost (this is usually set at 10-15%, though
circumstances can require any setting from 0 to 1)
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EOQ formula
The single item EOQ formula can be seen as the minimum
point of the following cost function:
Total cost = purchase cost + order cost + holding cost, which
corresponds to:
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EOQ formula
Taking the derivative of both the sides of the equation and
setting equal to zero, one obtains
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Solution
Solving for Q:
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Optimaum Balance
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EOQ Model
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works as
The first bin is stacked on top of, or in front of, the second
bin.
A recorder card is placed on the bottom of each bin.
Material is drawn from the first (or most accessible) bin only.
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Two-Bin System
bin.
The recorder card is used to replace items in the first bin.
Material is then drawn from the second bin while waiting for
receipt of the material on order.
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Two-Bin System
When the new material arrives, it is placed in the empty bin, and
the reorder card is returned to its proper place in the bin.
The procedure is continued, with material being selected from one
bin until it is depleted. The material is then replenished through
use of the reordering card.
As long as the quantity of the material in each bin is the same, one
bin can be first depleted and the order placed for the
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Item Search
It can be difficult experience for a maintenance planner who is not
familiar with the item numbers to locate the appropriate part in a
computer system.
Nouns and qualifiers are a way of simplifying a search.
A noun is a simple, meaningful name for the item, for example
pump. The qualifier adds more detail, such as hydraulic.
A search on this combination will bring up all hydraulic pumps in
the stock item master file.
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Item Search
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ABC analysis plot showing the accumulated value vs. Item nos
(not to scale) and volume
ENGG ZC242, Maintenance & Safety,
07/09/14, Lecture-8
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Automatic Replenishment
Suggested reorder functionality creates requisitions based on
reorder points (ROP) and reorder quantities (ROQ) that are stored in
the inventory record.
Once inventory levels for a part fall below the reorder point
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Multistores Capability
A multi stores capability enables an enterprise-wide view of
spare parts inventory that is stored at more than one
warehouse or off site by a third party
In a multi-plant environment or when maintenance
departments are distributed, visibility into inventory at the
various storerooms permits monitoring of parts availability
and service-level agreements across the enterprise as a
whole or on an individual basis
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Just-in-time (JIT)
JIT replenishment is a popular but sometimes controversial
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Just-in-time (JIT)
The best replenishment formulas cannot predict an emergency
breakdown, a vendor going out of business, a carrier going on
strike, or a sudden shortage of raw materials.
Being too conservative in stocking levels can result in the inability
to repair equipment in a timely manner or to keep the production
line running.
In asset management, the criticality of a part determines whether
it is a candidate for JIT.
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Lean Manufacturing
This is a similar concept with a broader scope. Lean
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New Approaches
Purchasing through the Internet is an effective means of
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asset management.
ENGG ZC242, Maintenance & Safety,
07/09/14, Lecture-8
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Barcode Solution
Like a library system, the programme tracks the item, where it is,
how often it is used, and when it is due back.
Reporting capabilities offer information on inventory value, asset
locations, and equipment usage.
In addition, the radio frequency scanners (the industry uses with
the system) mean that the operator is not chained to the
computer.
One can communicate with the PC in real time from anywhere in
the tool room.
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Barcode Solution
Scanned data is sent to the database instantly, and information
about the status of both the equipment and the employees can
be accessed from the hand-held.
If, for example, the employee at the counter has an overdue
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Improved Communication
The most significant aspect is that the plant has a consistent
method of tracking spare parts as well as consumables in its
entire site.
This will result in a change in purchasing habits. Orders are
no longer going out just because one spare part runs out of
an item.
Instead, operators can use the networked system to check for
the item's availability in other parts of the plant.
In addition, by forcing operators to catalog their spare parts,
the system will help to create an accurate count of its own
assets.
ENGG ZC242, Maintenance & Safety,
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ShotCode
High Capacity
Color Barcode
(HCCB)
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Wireless equipment
Ribbons
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BITS Pilani
Pilani Campus
Learning objectives
Purpose of lubricants
Societies who define the lubricant specifications
Various types of lubricants
Commercial grades of lubricants and their applications
Advantages of synthetic lubricants
Key definitions related to Lubricants
Stribeck curve in bearing lubrication
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Purpose
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Definition
A gas, liquid, or solid used to prevent contact of parts in
relative motion, and thereby reduce friction and wear.
In many machines, cooling by the lubricant is equally
important.
The lubricant may also be called upon to prevent rusting
and the deposition of solids on close-fitting parts.
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Extraction
of mineral oils
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Batch blending
of lube oil.
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Polyalphaolefins(PAO)
Synthetic esters
Polyalkylene glycols(PAG)
Phosphate esters
Alkylated naphthalenes
Silicate esters
Ionic fluids
Silicone
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Solid Lubricants
Graphite: Graphite structure (has layers of carbon atoms
separated at intervals of 0.6 nm (approximately). It has
high temperature withstanding capacity and as such the
powder can be added as an additive to base material to
form a paste.
Molybdenum disulphide.
Teflon: Used in pipe joints.
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Greases
Used in aggressive environments with temperature
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Pastes
These are similar to greases. They contain thickener.
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Additives
A large number of additives are used to impart performance
characteristics to the lubricants. The main families of
additives are:
Antioxidants
Anti wear
Metal deactivators
Corrosion inhibitors
Rust inhibitors
Friction modifiers
Extreme pressure
Antifoaming
Demulsifying/emulsifying
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Application
Automotive:
Petrol engine oil
Diesel engine oil
Two stroke engine oil
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Application
Hydraulic fluids:
Industrial
Hydraulic fluid
Compressor oils
Gear oils
Aviation:
Gas turbine engine oils
Piston engine oils
Marine:
Top engine oil
Crankcase fluids
Stern tube lubricants
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Comparison
Base Oils
Advantages
Limitations
Petroleum
Hydrocarbon
Synthetic
hydrocarbon
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Comparison
Base Oils Advantages
Polyglycols
/Polyethers
Limitations
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Comparison
Base Oils
Synthetic
esters
Advantages
Minimum viscosity change with
temperature
Low volatility
Better load-carrying capacity
Applicable in low temperatures
Stability for oxidation
Good antiwear properties.
Good lubricity
Limitations
Cannot be used in
all the plastics
and elastomers
due to
compatibility
problems
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Comparison
Base Oils
Silicones
Advantages
Limitations
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Comparison
Base Oils
Advantages
Limitations
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Comparison
Base Oils
Polyphenylethers (PPE)
Advantages
Limitations
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Comparison
Base Oils
Multiply
alkynated
cyclopentane
Advantages
Limitations
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Performance of Synthetic
Lubricants in Varied Temperature
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Definitions in Lubrication
Apparent Viscosity
The viscosity of lubricant measured at a given shear rate
for cases where viscosity is dependent on shear rate.
Asperities
Microscopic projections from a surface particularly on a
sliding or a bearing surface which result from machining
operation or finishing treatment. They are the primary
causes of friction if there is insufficient film of lubrication
between sliding surfaces.
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Definitions in Lubrication
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Definitions in Lubrication
Base Number
A measure of basicity (alkalinity) of a lubricant, which is
obtained by reacting it with acid of known strength until
neutralization.
Boundary Lubrication
The condition in which lubricant is present between two
sliding surfaces, but in insufficient quantity and provides a
broken film. Generally, this occurs when the relative sliding
speed of two surfaces is less than 0.1 cm/s.
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Definitions in Lubrication
Bright Stock
High viscosity base oil made from the bottoms of the
vacuum distillation column, by deasphalting and dewaxing.
Centipoise
A component unit of viscosity, equal to one-hundredth of
the unit of viscosity, Poise.
Centistokes
A unit of viscosity commonly used when a liquid falls
through a capillary tube under its own weight. This is
related to centipoise by the equation:
Centistoke x Density = Centipoise
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Definitions in Lubrication
Cloud Point
As oil is progressively cooled the temperature at which
wax starts to separate from the oil. producing cloudy
appearance.
Coefficient of Friction
This measures degree of friction between two surfaces.
This is a function of a normal force acting on the body
which is moving or sliding, surface area of contact, velocity
of sliding body, quality of surface interface, and
temperature at the interface.
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Definitions in Lubrication
Dispersant
An engine oil additive whose primary function is to hold in
suspension solid and liquid contaminants, thereby passivating
them and reducing engine deposits and at the same time
sludge deposition is reduced. Ashless dispersant is a polymerbased material, which are particularly useful in holding water
in suspension in gasoline engine oils, as well as suspending
solid particles.
.
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Definitions in Lubrication
Extreme Pressure
Whenever surfaces are sliding against each other under
heavy loads like hypoid gears, the lubricants needs to
have properties to withstand such pressures.
Therefore, additives are added to the base stocks,
thereby, lubricants can react with asperities of the metal
surface and forms compounds, which can readily shear
without having to disturb the base metals.
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Definitions in Lubrication
Film Strength
Property of lubricant indicating its effectiveness to lubricate
under boundary conditions. This is enhanced by addition
of long chain polar molecules.
Flash Point
The lowest temperature at which the vapours from heated
products will ignite when exposed to air.
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Definitions in Lubrication
Kinematic Viscosity
This is a measure, which shows the liquid's resistance to
flow under the force of gravity. This is nothing but
(absolute viscosity)/(density).
Mass Spectrometer
This is an instrument wherein the spectrum is formed by
passing ionized fragments of petroleum products in a
magnetic field. From the spectrum the constituents of
hydrocarbons are evaluated either by photographically or
by electronically.
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Definitions in Lubrication
SAE Viscosity
It is a classification of viscosity of lubricants by Society for
Automotive Engineers (SAE). Winter grade oils have suffix
"W" such as SAE 10W, where as summer grade oils do
not have any suffix. They represent viscosity of oil at
100C. They are merely represented as SAE 40.
If an oil is multi grade, i.e. it can be used both in winter as
well as in summer, the specification will be SAE 10 W-30.
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Definitions in Lubrication
Fluid film lubrication
It is the lubrication regime in which through viscous
forces the load is fully supported by the lubricant within
the space or gap between the parts in motion relative to
one another (the lubricated conjunction) and solidsolid
contact is avoided.
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Definitions in Lubrication
Hydrostatic lubrication is when an external pressure
is applied to the lubricant in the bearing, to maintain
the fluid lubricant film where it would otherwise be
squeezed out.
Hydrodynamic lubrication is where the motion of
the contacting surfaces, and the exact design of the
bearing is used to pump lubricant around the bearing
to maintain the lubricating film. This design of bearing
may wear when started or stopped, as the lubricant
film breaks down.
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Definitions in Lubrication
Elastohydrodynamic lubrication
The opposing surfaces are separated, but there occurs
some interaction between the raised solid features
called asperities, and there is an elastic deformation on
the contacting surface enlarging the load-bearing area
whereby the viscous resistance of the lubricant becomes
capable of supporting the load.
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Definitions in Lubrication
Boundary lubrication
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Definitions in Lubrication
Spectroscopy
This is an analytical technique whereby any type of radiation
whether it be visible, x-ray, infrared, ultraviolet, microwave is
split up into a spectrum and from the spectral indication
(Which is formation due to different wavelength of radiation),
presence of different contaminants are measured in a
lubricant.
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Definitions in Lubrication
Thixotropic
It is a definition of a process whereby grease becomes
liquefied when subjected to shear force.
Total Acid Number
It is the content of acid in a lubricant obtained by titration
with alkali up to a pH value of 7.
Total Base Number
Total alkalinity in a lubricant obtained by titration with acid
up to a pH value of 7.
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Definitions in Lubrication
Tribology
Composite scientific study of friction, wear and lubrication
so as to minimize the harmful effects upon machinery.
Viscosity Index
It is a representation in a scale of 0-100 the viscosity of
lubricant varying under temperature.
Viscosity Modifier
Polymer additive which improves viscosity of an oil
thinning due to temperature.
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Definitions in Lubrication
Inhibitor
A chemical substance, which prevents any unersirable
reaction.
Oiliness agent
A polar additive used for improving the lubricity of
mineral oil.
Passivator
An additive which reacts with metallic surfaces to
prevent any corrosion by the lubricant or to prevent
oxidation.
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Definitions in Lubrication
Polar molecules
In chemical, the molecules have one end electrically
positive and the other end negative. Polar molecules are
attracted to surfaces and many additives consist of polar
molecules.
Pour point
A test, which indicates the gelling tendency of paraffin
based oils at low temperature.
Silicones
Organosiloxane polymers used as stable synthetic
lubricant.
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Thanks
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