MAINTENANCE MANAGEMENT SUBMISSION ASSIGNMENT: 1

Date: 25th August 2011

Submitted by: Mukesh Kumar DFT VII

Define Maintenance Engineering. What is maintenance Objectives? Explain different Maintenance Approaches...

Maintenance Engineering is the discipline and profession of applying engineering concepts to the optimization of equipment, procedures, and departmental budgets to achieve better maintainability, reliability, and availability of equipment. (Wikipedia, as accessed on 23rd august 2011) The application of techniques, engineering skills, and effort, organized to ensure that the design and development of weapon systems and equipment provide adequately for their effective and economical maintenance. (Dictionary of Military and Associated Terms. US Department of Defence 2005) Maintenance is the work that keeps things running and finds future problems before the problem stop the machine running at all. Maintenance engineering ensures Reliability, Availability & maintainability of any machine. Objectives of Maintenance: The purpose of maintenance is to attempt to maximize the performance of equipment by ensuring that such equipment performs regularly and efficiently, by attempting to prevent breakdowns or failures, and by minimizing the losses resulting from breakdowns or failures. In fact it is the objective of the maintenance function to maintain or increase the reliability of the operating System as a whole. The basic maintenance objectives are to (1) Provide maximum availability of safe and serviceable machines and (2) Provide maximum economic service life of machines. (As per Page: 7.2 Fleet Maintenance\Maintenance Objectives, Last Updated: 08/30/2005 09:33 AM (NASA official fleet management handbook))

However at Micro following objectives can be achieved through maintenance:1.) Minimize the downtime factor and try to guarantee the reliability of equipment throughout its working life. 2.) Minimize the technician maintenance time. 3.) Diminish the risk of personnel injury resulting from maintenance tasks and by the use of organizations equipment. (Rich, 2001; Yang et al, 2003). 4.) Minimize and control the cost resulting from maintenance activities (Yang et al, 2003). 5.) Collecting the experience gained from each breakdown and the development of skills from personnel who operate within industry (Rich, 2001; Yang et al, 2003).

Maintenance approaches: There are various types of maintenance approaches followed in manufacturing industry. The following are the various types of maintenance approaches. Maintenance approaches

Planned maintenance

Breakdown maintenance

Preventive

Predictive

Corrective

CBM

RCM

( as per Maintenance Engineering slide-14, by Mr Arivoli N. ,assistant professor, NIFT Bangalore)

Planned Maintenance: Planned Maintenance (PM) or Scheduled Maintenance is any variety of scheduled maintenance to a machine. Specifically, Planned Maintenance is a scheduled service visit carried out by a competent and suitable agent, to ensure that an item of equipment is operating correctly and to therefore avoid any unscheduled breakdown and downtime. (Wikipedia, as accessed on 23rd august 2011) Plan can be based on equipment running hours, date based, or for vehicles distance travelled. Good example of PM program is car maintenance. After so many kilometres or miles oil should be changed, parts renewed... All portions of planned maintenance are important and are necessary to be effective. Planned maintenance is not just a planning and scheduling function stuck on the side of a general "fire fighting" type maintenance organization. It must be complete to be effective, and leaving one feature out will seriously hamper the program. Advantages of planned maintenance system:
  

Easier planning of maintenance and ordering spares. Costs are distributed more evenly. No initial costs for instruments for supervision of equipment.

Disadvantages of planned maintenance system:



More expensive due to more frequent parts change.

Breakdown maintenance: It is a type of maintenance process in which repairs or replacements performed after a machine has failed to return to its functional state following a malfunction or shutdown. It means that people waits until equipment fails and repair it. Such a thing could be used when the equipment failure does not significantly affect the operation or production or generate any significant loss other than repair cost.

Preventive maintenance: It is a daily maintenance (cleaning, inspection, oiling and re-tightening), design to retain the healthy condition of equipment and prevent failure through the prevention of deterioration, periodic inspection or equipment condition diagnosis, to measure deterioration. Just like human life is extended by preventive medicine, the equipment service life can be prolonged by doing preventive maintenance. Preventive maintenance (PM) has the following meanings: 1. The care and servicing by personnel for the purpose of maintaining equipment and facilities in satisfactory operating condition by providing for systematic inspection, detection, and correction of incipient failures either before they occur or before they develop into major defects. 2. Maintenance, including tests, measurements, adjustments, and parts replacement, performed specifically to prevent faults from occurring. (Wikipedia, as accessed on 23rd august 2011) Preventive maintenance is conducted to keep equipment working and/or extend the life of the equipment. Long-term benefits of preventive maintenance include:
y y y y

Improved system reliability. Decreased cost of replacement. Decreased system downtime. Better spares inventory management.

Predictive Maintenance: This is a method in which the service life of important part is predicted based on inspection or diagnosis, in order to use the parts to the limit of their service life. Compared to periodic maintenance, predictive maintenance is condition based maintenance. It manages trend values, by measuring and analysing data about deterioration and employs a surveillance system, designed to monitor conditions through an on-line system. Predictive maintenance techniques help determine the condition of in-service equipment in order to predict when maintenance should be performed. This

approach offers cost savings over routine or time-based preventive maintenance, because tasks are performed only when warranted. Predictive maintenance allows plant management to control the machinery and maintenance programs rather than vice versa. In a plant using predictive maintenance, the overall machinery condition at any time is known, and much more accurate planning is possible. Corrective Maintenance: Corrective maintenance can be defined as a maintenance task performed to identify, isolate, and rectify a fault so that the failed equipment, machine, or system can be restored to an operational condition within the tolerances or limits established for in-service operations. (Wikipedia, as accessed on 23rd august 2011) Activities undertaken to detect, isolate, and rectify a faults so that the failed equipment, machine, or system can be restored to its normal operable state. It improves equipment and its components so that preventive maintenance can be carried out reliably. Equipment with design weakness must be redesigned to improve reliability or improving maintainability.

CBM (Condition Based Maintenance): Condition-based maintenance (CBM), shortly described, is maintenance when need arises. This maintenance is performed after one or more indicators show that equipment is going to fail or that equipment performance is deteriorating. (Wikipedia, as accessed on 23rd august 2011) Advantages of CBM:
  

Improved system reliability. Decreased maintenance costs. Decreased number of maintenance operations causes decreasing of human error influence.

Disadvantages of CBM:
y

High installation costs, for minor equipment items more than value of equipment. Unpredictable maintenance periods are causing costs to be divided unequally. Increased number of parts (CBM installation) that need maintenance and checking.

For example, suppose a critical piece of equipment is monitored continuously to ensure that some temperature is within an acceptable range. If the temperature rises above the upper limit, a control loop can activate a fan to cool the overheated area until the temperature returns to an acceptable range. RCM (Reliability Centred Maintenance): Reliability Centred maintenance is a step-by-step instructional tool for how to analyse a system s all failure modes and define how to prevent or find those failures early. Reliability Centred Maintenance, often known as RCM, is a process to ensure that assets continue to do what their users require in their present operating context. (Wikipedia, as accessed on 23rd august 2011) RCM offers four principal options among the risk management strategies:
   

On-condition maintenance tasks. Scheduled restoration or discard maintenance tasks. Failure-finding maintenance tasks. One-time changes to the "system" (changes to hardware design, to operations, or to other things). When RCM is very useful Tool:
y y

When designing, selecting, and installing new systems in a plant. When setting up Preventive Maintenance for complex equipment and systems we are not clear on how they work. When teaching people the basics of reliability it helps to explain the matters in a detailed fashion using RCM.

References: 1.) Power point slides on Maintenance Engineering by Arivoli N., Assistant Professor NIFT Bangalore. Webpages: 1.) www.wikipedia.com including http://en.wikipedia.org/wiki/Maintenance_engineering (as accessed on 23rd august 2011) http://en.wikipedia.org/wiki/Planned_maintenance (as accessed on 22nd august 2011) http://en.wikipedia.org/wiki/Predictive_maintenance(as accessed on 22nd august 2011) http://en.wikipedia.org/wiki/Corrective_maintenance(as accessed on 22nd august 2011) http://en.wikipedia.org/wiki/Reliability_centered_maintenance(as accessed on 22nd august 2011) 2.) http://www.idcon.com/reliability-tips-610.html(as accessed on 23rd august 2011) 3.) http://www.dliengineering.com/vibman/predictivemaintenance.htm(as accessed on 22nd august 2011) 4.) http://www.adrelia.com/doc/object%20mm%20fnl.pdf(as accessed on 22nd august 2011) 5.) http://nodis3.gsfc.nasa.gov/npg_img/Portal/graphicview/72maintenanc eobjectives.htm(as accessed on 22nd august 2011) Articles: 1.) Maintenance Engineering White Paper by Karl Kelton and Brent Chertow (As published on October 2003) 2.) A knowledge based Maintenance programme by Prof.Mahantesh Nadakatti (as published in IET Manufacturing Engineer, April/May 2006)

What are the Tasks and Responsibilities of Maintenance engineer in Garment Industry?

A Maintenance Engineer works as a senior reliability and is responsible for evaluating the reliability of the sewing equipment and work processes. In addition, he or she is also responsible for monitoring and carrying out of all reliability enhancement plans of machines. Tasks and responsibilities of Maintenance Engineer: 1.) The Maintenance Engineer provides technical guidance for maintenance and reliability data by evaluating the SAP data history for accuracy, and ensuring compliance with the best reliability practices. 2.) The Maintenance Engineer is responsible for establishing and monitoring critical equipment analysis and condition monitoring programs. 3.) The Maintenance Engineer assists in new installations design as well as any facility design changes. 4.) The Maintenance Engineer must develop reliability strategies to monitor equipment performance. (from case study Maintenance Technician, Stephen, published in 2003) Functions Performed by Maintenance Engineer in Garment Industry: 1.) Designing maintenance strategies, procedures and methods. 2.) Planning and scheduling planned and unplanned work. 3.) Diagnosing breakdown problems. 4.) Carrying out quality inspections on machines. 5.) Arranging specialist procurement of fixtures, fittings or components. 6.) Controlling maintenance tools, stores and equipment. 7.) Monitoring and controlling maintenance costs. 8.) Writing maintenance strategies to help with installation and commissioning guidelines. (Through Canadian institute of Mining, Montreal in 2002) Duties of Maintenance engineer: 1. Maintenance Plan Maintenance engineers implement and schedule a maintenance plan as a preventive measure for each piece of machine under their direction. This plan

is designed to decrease the number of breakdowns or work stoppages because of equipment failure. Part of this plan is performing routine maintenance. 2. Recruitment The maintenance engineer is responsible for recruiting and training technicians on the correct preventive maintenance of each piece of machine. This includes identifying qualified technicians to perform the duties outlined in the maintenance plan. 3. Inventory, Monitor, Inspect A maintenance engineer inventories, monitors and inspects equipment in order to maintain it. This includes identifying worn components so they can be replaced before a breakdown or work stoppage occurs. Inventory each piece of equipment and its parts to see which spare parts need to be ordered or kept in the department to minimize down-time. 4. Cost and Performance The maintenance engineer is also responsible for evaluating and documenting each machine. This includes the cost of the machine and its performance. The documentation will help the company in determining the effectiveness of the machine and its preventive maintenance plan. 5. Repairs A maintenance engineer schedules and makes timely repairs on each piece of equipment when it breaks down or is in need of preventive maintenance. Emergency repairs are also a component of this duty. Completing effective emergency repairs will minimize the time lost from unanticipated work stoppage because of misuse or equipment failure. (Maintenance Engineering White Paper by Karl Kelton and Brent Chertow, Published in 2003)

References:

Web Pages: http://www.atlas4jobs.com/onshore-jobs/maintenance-engineer/jobdescription (as accessed on 23rd august 2011) http://www.prospects.ac.uk/maintenance_engineer_job_description.htm (As accessed on 23rd august 2011) http://www.ehow.com/list_6303444_duties-maintenance-engineer.html (As accessed on 22rd august 2011) http://answers.yahoo.com/question/index?qid=20071027221714AAfzlA3 (As accessed on 21rd august 2011) Articles: 1.) Maintenance Engineering White Paper by Karl Kelton and Brent Chertow (As published on October 2003)

Hierarchy of Maintenance Department of Sahi Exports:

General Manager

Manager TPM

Senior MechanicEmbroidery and Cutting

Senior Technical Assistant

In chargeMaintenance, Stores

In charges- TPM Production floor wise

In charge - CMD

In charge TPM Folders

Product Safety Officer

Mechanic Cutting section Mechanic Embroidery Section

Boiler / DG Operator

Stores Helpers

Senior Mechanics

Mechanics Batch Setting

Profile maker / Folder Assistant

Needle issue Helpers

Electricians

Floor Mechanics

Mechanics Overhauling

Needle detection Helpers

Carpenters

Plumbers

Painter