IMWT160
What is Maintenance
The activity carried out to prevent the
occurrence of failure and activity carried
out after failure to rectify the defect is
called maintenance.
Maintenance Mission
To maximize and sustain the reliability of all
manufacturing equipment and provide the
capability to produce high quality products
at the lowest possible cost over the life of
the plant.
Objective of Maintenance
The primary objective of maintenance is to
increase the operational reliability and
personnel safety at minimum cost.
Failures are inevitable due to natural wear
and tear.
Production Vs Maintenance
The total production that can be obtained
from a plant depends upon its capacity
and the number of working hours.
Interruption on account of breakdown
reduce the total time available for
production. Therefore
Production = Capacity x Availability.
Downtime
The duration by which any machine goes
out of production due to break down is
called downtime.
The downtime is the total time taken on
account of maintenance to rectify the fault.
The total time taken on account of
maintenance involves the time actually
spent by the respective maintenance team
to correct the fault and waiting time for
want of spares required for rectify the
defect.
Downtime = Repair time + waiting time
Waiting Time
The waiting time is the most unproductive
elements of total downtime . The reason
for waiting time could be : Want of spares
Want of crew members
Lack of communication.
Lack of proper supervision
Total Downtime
PRODUCTION
CAPACITY
AVAILABILITY
MAINTENANCE
Role of Maintenance
Maintenance play an important role in a
manufacturing activity where plants and
machineries are employed. No machine
can work indefinitely and produce
continuously . There is going to be some
interruptions in production due to machine
failures. At the same time higher the
number of failures greater will be the loss
of availability and production.
Role of Maintenance
The frequent failures cause frequent
interruption in the production and the
plant and machines become unreliable.
This degree of uncertainty in production
due to machines failures is termed as
reliability .
Higher the reliability in operation lesser will
be the failure or vice versa
EQUIPMENT MALFUNCTIONS
Equipment malfunctions have a direct
impact on:
Production capacity
Production costs
Product and service quality
Employee or customer safety
Customer satisfaction
PLANNED MAINTENANCE
The purpose of planned maintenance is to
ensure the equipment conditions at their
best with the minimum cost, enabling
equipment to function at an optimal level
whenever operation is required
Breakdown Maintenance
No regular inspection and replacement are carried out.
Equipment is restored after breakdown.
Corrective Maintenance
It involves equipment improvements that result in
maintainability and reliability improvements, prevention of
breakdowns recurrence, maintenance time reduction,
production time improvement, etc.
Maintenance Prevention
It involves feedback of information and new equipment
development based on the feedback.
Preventive Maintenance
It involves equipment health control and fixing before
failure.
contribute
replacement:
MAINTENANCE ORGANIZATIONS
ASSISTANT
CHIEF
ENGINEER
CHIEF
ENGINEER
ELECTRICAL
LEAD PERSON
MECHANICAL
LEAD PERSON
WELDING
LEAD PERSON
INSTRUMENTAI
ON LEAD
PERSON
STEAM PLANT
LEAD PERSON
OFFICE
SUPPORT
LEAD PERSON
ELECTRICIAN
MILLWRIGHT
WELDER
INSTRUMENTA
TION
TECHNICIAN
OPERATING
ENGINEER
OFFICE
SUPPORT
PERSON
MULTISKILLED
MULTISKILLED
MULTISKILLED
Planning
Planning
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
1- P - PLAN
4- A - ACT
2- D - DO
3- C - CHECK
Planning Procedures
Planning Procedures
Long-Range Planning
Medium-Range Planning
Short-Range Planning
Scheduling
Scheduling