MAINTENANCE

DEFINITION:
is the process of keeping the machine and equipment in good working condition so that the
efficiency and life of the machine is increased.

TYPE OF MAINTENANCE:
1- BREAKDOWN (run to failure)
it means that people wait untile equipment fails and repair it . repair costs are less than other
type of maintenance

DISADVANTAGES OF IT :

·0 Increases chances of accidents and less safety for both workers and machines.

·1 equipment not maximised.

·2 unpredictability

2-preventive (time-based)
its a daily maintenance ( cleaning , oiling , and inspection ) desine to retain the healthy
condition of equipment and prevent failure through the prevenation of delerioration .

periodic inspection or equipment condition diagnosis .

DISADVANTAGES OF IT :

·3 catastrophic failure still a risk

·4 performance of maintenance based on SCHEDULED not required

·5 risk of damage when conducting unneeded maintenance

ADVANTAGES :

·6 increased equipment life

·7 saved energy cost resulting from equipment running from pick efficiency

·8 over all saving between 12% to 18%

 ·9 less overtime with unexpected repairs

3-PREDICTIVE (CONDITION-based):
In predictive maintenance, machinery conditions are periodically monitored and this
enables the maintenance crews to take timely actions, such as machine adjustment, repair
or overhaul .

it makes use of human sense and other sensitive instruments, such as ( audio gauge,
vibration analyzer, amplitude meter, pressure, temperature and resistance strain gauges
etc) .

Unusual sounds coming out of a rotating equipment predicts a trouble .

DISADVANTAGES OF IT :

·10 incresed stuff training for analysing data.

·11 increased investement of diagnostic equipment

ADVANTAGES :

·12 over all saving between 8% to 12% over preventive maintenance

·13 more safe for human and enviroment

4-Proactive
You take steps before things break in order to prevent them from breaking

Proactive maintenance leads to all the ways you can schedule work orders and labor, as
well as measure spare parts and collect metrics that may give you information to say when
it’s necessary to take action.

PROBLEMS IN MAINTENANCE :
·14 Lack of management attention to maintenance

·15 Little participation by accounting in analyzing and reporting costs

·16 Difficulties in applying quantitative analysis

·17 Difficulties in obtaining time and cost estimates for maintenance works
 ·18 Difficulties in measuring performance

·19 Production load

·20 Continuous operation

·21 Unskilled staff

CAUSES OF PROBLEMS IN MAINTENANCE:

·22 Failure to develop written objectives and policy

·23 Inadequate budgetary control

·24 Inadequate control procedures for work order,service requests etc.

·25 Infrequent use of standards

·26 To control maintenance work

·27 Absence of cost reports to aid maintenance planning and control system

·28 Unavailability of spares

MAINTENANCE OBJECTIVES:
·29 Must be consistent with the goals of production (cost,quality,delivery,safety)

·30 Must be comprehensive and include specific responsibilities

PURPOSE OF MAINTENANCE:
1. To keep equipment system operative.

2. Attempt to maximize performance of production equipment efficiently and regularly

3. Prevent breakdown or failures

4. Minimize production loss from failures

5. Increase reliability of the operating systems

6. To keep operation safe

7. To prevent leakages losses

 Maintenance and care of the regular engine lathe
Like all machine tools, regular engine lathes are subject to permanent wear.

By constant care and maintenance of the machines wear can be controlled and kept low.

The following principles have to be observed:

·31 - The operating instructions are decisive for the use and maintenance of the machine.
They must be carefully observed.

·32 - Before beginning the daily work, all parts of the machine that have to be lubricated by
hand have to be oiled according to the instructions. Unsufficient lubrication leads to
early abrasion. For centralized and circulating lubrication make sure that the quantity of
oil is sufficient.

·33 The oil strainers have to be cleaned regularly and at the required intervals.

The following principle applies to the lubrication of a machine:

·34 The prescribed quantity of the prescribed lubricant to the respective lubrication points
of the prescribed time.

·35 - Before putting the machine into operation make sure that all levers are in their correct
positions. Wrong lever positions may lead to breaks.

·36 - All guideways must be protected against, chips, acale, dust and abrasion of any kind.
Otherwise they will wear out soon and inaccurate work would be the result.

·37 - Guideway parts which are not used must be protected against contamination by
protective equipment.

·38 - Make sure that the workplace is always in order. Clamping means and change gears
must be kept in their proper places. On the regular engine lathe, the required tools must
be well ordered and ready to hand on the protective boards.