MAINTENANCE ENGINEERING

Maintenance is the routine and recurring process of keeping a particular machine or

asset in its normal operating condition. So that it can deliver the expected
performance or service without any loss or damage.
Maintenance is the act of repairing or servicing equipment
The responsibility of the maintenance function should be to ensure that production
equipment / facilities are available for use for maximum time at minimum cost
within stipulated time period.
Role of maintenance at various stages can increase productive life of equipment and
defer the capital expenditure.
Proper maintenance work raises the level of equipment performance and
availability, reducing the need for adding new equipment thus making the end
product competitive in the market.
An efficient maintenance not only reduces the probability of breakage of machine
elements shut down of machine, hampering the scheduled production, but at the
same time, such a function enhances the efficiency and accuracy of the production
machines, lengthening their span of life.

PLANNING:
It is the process of determine how the organization can get where it wants to go.
The basic purpose of planning is to reduce the risk of uncertainties and to initiate a
coordinated effort with in the organization for the purpose of organizational
success.
Planning ensures the smooth operation of the system.
Three types of planning in Engineering system
1.Long Range Plan (span of 5 to 10 Years)
2.Short Range Plan (shorter period of time say 1 or 2 years)
3.Planning for Immediate Activity (It is a routine activity and it is done at the
working level when required )
Maintenance Planning :
Maintenance planning is the task of organizing resources to carry out a job
satisfactorily at reasonable cost within a specified period of time.
Maintenance planning should be carefully designed in such a manner it is able to
tackle the emergency maintenance as well as to ensure that maintenance workforce
is fully utilized.

OBJECTIVES OF MAINTENANCE PLANNING:

1.To achieve minimum breakdown and to keep the plant in good working condition at the
lowest possible cost.
2.To ensure the availability of the machines and service in an optimum working condition
3.To keep the machines and other facilities in a condition to be used to achieve the
maximum profit without any interruption or hindrance.
4.To keep the time schedule of delivery to the customers
5.To meet the availability requirements for critical equipments
6.To keep the maintenance cost as low as possible for non critical equipments
7.To control the cost of maintenance related activities
8.To provide effective and trained supervision
9.To ensure safety to the workers
10.To meet the quality requirement of the product
11.To increase the profits of production systems. To establish a satisfactory working
condition.

PRINCIPLES OF MAINTENANCE:
Maintenance principles are followed in a system to guide the staff to work efficiently
and effectively to achieve the overall objectives .
The main areas of work governed by these principles are:
1.Plant management in maintenance work : Main role of the maintenance function is
to provide safe and effective operation of the equipment to achieve the desired targets
on time with economic usage of resources.
2.Production and maintenance objectives: The achievement of desired goals of the
production system is to be supported by both the production and maintenance
department to ensure smooth and successful operation of the industry.
3.Establishment of work order and Recording system: Work order for the maintenance
function indicates the nature of work to be performance and the series of operations to
be followed to execute a particular job. It is necessary to maintain proper records and
entries to monitor the maintenance function. This record is useful in formulating the
future maintenance plans and to meet the desired objectives of the organization.

4. Information Based Decision Making: The information is used to meet the man power
and spare parts requirements of the industry.
5.Adherence to planned maintenance strategy: It includes the use of manufacturers
information on the life and maintenance schedules of the equipment and other
materials resources available.
6.Planning of maintenance functions: All the maintenances functions are to be carefully
executed by way of proper planning to ensure the effective utilization of manpower
and materials.
7.Manpower for maintenance: The manpower requirements should also satisfies the need
arising in cases of overhauls, component replacement, emergency and unscheduled
repairs.
8.Workforce control: Determination
of exact workforce required to meet the
maintenances objectives of the system is difficult task due to the element of
uncertainty

9.Role of spare parts: The system should have good quality tools and that tools available in
required quantities to ensure the proper function of the maintenance works.
10.Training of the maintenance work force; Training helps the workforce to learn about the
modern techniques, recent trends in maintenances, Knowledge of sophisticated
instruments and to chalk out a strategy to meet the growing demands of the industry.
VARIOUS FACTOR TO BE CONSIDERED IN MAINTENANCE PLANNING:
1.Job Distribution: The first and foremost task in maintenance planning is the distribution
of the jobs to the personnel for preventive and emergency maintenance works. The
distribution is also to ensure that neither underutilization nor over utilization of
resources is done.
2.Programme: It is a well formulated combination of the available skills and resources that
ensures optimum and appropriate utilization to meet the objectives of the organization.
Maintenance programme involves
a. Selection of activities for maintenance
b. Determination of the frequency of preventive maintenance
c. Decision on the cost effective methodology

3. Manpower Allocation: The central idea of manpower allocation can be drafted using
the information available about the skill level of personal deputed for the
maintenance and planning the task to meet the objectives and to keep reliable
records for analysis of results of maintenance.
4.Staffing: Staffing is dependent upon the ability of the organization to tackle the regular
as well as attending the unforeseen situation. Staffing should be sufficient to handle
preventive and emergency maintenance task
5.Planning Techniques; Planning techniques are required to develop the overall master
plan, for scheduling and execution. Planning methods are Gantt charts, milestone
method, critical path method9CPM0, Programme Evaluation Review
Techniques(PERT).
6.Planning Procedures Four steps in planning procedures
a. Organizing maintenance resources to ensure their effective use in future
b. Scheduling the resources for the planned period
c. Execution of plans according to the schedules
d. Establishing a feedback system for all the above processes to identify the
deficiences of each process

7.Estimation of maintenance works: It is used to find out the quantity and quality of the
maintenance work. This will help in allocation of the required manpower.
8.Maintenance Control; Maintenance control is the auditing technique to ensure the
effective utilization of maintenance budget. This accountability controls and
improves the quality of manpower and material utilization in an organization.
Combined preventive maintenance and emergency maintenance planning:
If the maintenance planning need both the preventive and emergency demands then it
should follow the three factors
(a) Organizational Goals: Maintenance planning must be in accordance with that of
the organization goals. Maintenance Needs Analysis(MNA)should be carried out to
identify the role of piece of equipment or asset in achieving the desired objectives of
the organization. The planned work should be executed out to improve the
performance of the production system.
(b)Policies: Fault oriented maintenances policies are evolved by the maintenances
department. The policies must be well defined so that timely implementations of
maintenance functions are ensured.

( c) Procedures: The procedures of the work must be well defined and standardized
without any confusion to the workforce. The development of procedures includes
the design of the inspection form, interval of reporting, issues of maintenance tools
etc.
Importance and Benefits of sound maintenances Management systems:
The profit of any industry depends solely on the return on the investment. The capital
cost and operating costs are the major factors in any industrial investment. The
higher return on investment is possible to achieve only if the equipment and other
machineries are in proper working condition to meet the designed as well as desired
levels of performance.
Various Benefits of sound maintenances Management systems are
1.Minimization of downtime
2.Improvement in availability of system
3.Extended life of equipment
4.Safety and smooth operation of the process
5.Provide adequate back up supply

6.Minimization

of normal expected wear ant tear of equipment

7. Safety of the personal involved in the organization

8.Provide proper working environment
9.Cost effective maintenance boost the profit of the production system
Reliability:
Reliability is the probability of performing a specified functions for a specified
period of time
It refers to the likehood that equipment will not fail during its operation.
Reliability may also be defined as the probability that a component/ system, when
operating under given condition will perform its intended functions adequately for a
specified period of time.
The application of reliability techniques to any equipment helps to identify the flaws
in system design, compare several possible configurations, minimize downtime,
maximize operational readiness, reduce operating costs and develop maintenance
polices.

Four important factors required in the determination of reliability are:

1.Reliability expressed as probability
2.Adequate performance requirements
3.Duration of adequate performance
4.Environmental or operating conditions
1.Reliability expressed as probability: Probability is the ratio of the number of times we
can expect an event to colour to the total number of trials undertaken. A reliability
factor can be expressed as probability. A reliability factor equal to one means that
device performs satisfactorily for the prescribed duration under the given
environmental condition.
A reliability factor zero means all the equipment would fail to meet the required
performance level
2.Adequate performance requirements: This defines the role expected of a device or
system. A system may perform satisfactorily even though one or more components
may not be functioning
.

3.Duration of adequate performance: It is used to state the time up to which the desired
performance of the system is achieved under the given operating conditions.
4.Environmental or Operating conditions: It indicates the prevailing conditions at which
the system is under operation.
Reliability is the probability of a device performing its purpose adequately for the period
intended under the given operating condition
Two types of reliability
1. Inherent reliability ; It is associated with the quality of the material and design of
machine parts
2.Achievable Reliability : It depends upon other factors such as maintenances and
operation of the equipment.
The total reliability of any equipment is a function of design , maintenance and field
operational reliability.

Machine Availability: The availability of a machine or service over a specified time can be
represented as

UT
A
UT DT
Where
A is the availability of the machine over a specified time
UT is the machines uptime during the specified time
DT is the machines downtime during the specified time
UPTIME : Up time of a machine / service is thus the time for which it is actually
available to complete the desired function.
DOWNTIME; Downtime or outage of a machine is the period of time during which it is
not in an acceptable working condition.
The availability of equipment in terms of its working effectiveness called as operational
availability(OA)

Availability is the ratio of the time at which equipment is available for the designated
operation/service to the total time of operation and maintenance of the equipment
Three types of availability based on the time element:
1.Inherent Availability: It is the probability that a system or equipment shall operate
satisfactorily when used under prescribed conditions in an ideal support
environment without any scheduled or preventive maintenance at any given time
Inherent availability = MTBF / (MTBF+MTTR)
ideal support environment means the ready availability of tools, spare parts ,
manpower, manual etc.
2.Achieved Availability: It is the probability that a system or equipment shall
operate satisfactorily when used under prescribed conditions in an ideal support
environment without any scheduled or preventive maintenance at any given time

Achieved availability = MTBF / (MTBF+M)

M-

Mean active maintenance downtime resulting from preventive and corrective

maintenance.

3.Operational Availability: In an industrial system, a certain amount of delay will always

caused by time element such as downtime and administrative down time.
Operational availability is the probability that a system or equipment shall operate
satisfactorily when used under prescribed conditions in an actual supply
environment without any scheduled or preventive maintenance at any given time
Achieved availability = MTBF / (MTBF+MDT)
MDT- Mean downtime including the supply downtime and administrative down time

OT IT
OA
OT IT AD RT

Where
OT is the operating time
IT is the idle time
AD is the administrative delay or operational delays
RT is the repair time

Mean Time to Repair(MTTR) :

Mean time to repair(MTTR) is the arithmetic mean of the time required to perform
maintenance action. MTTR is defined as the ratio of total maintenance time and
number of maintenance action
MTTR= Total maintenance time / Number of maintenance action
Maintenance Action Rate: Maintenance action Rate is the number of maintenance action
that can be carried out on equipment per hour

= 1/ MTTR
MTTR

Mean time to Repair

Mean time to Recovery

Mean time to Restore
Mean time to Respond
Mean time to Replace
M Mean, Minimum, Maximum

Mean Waiting Time(MWT): Mean waiting time is the ratio of Total machine hours lost
due to waiting for materials or labour to the total number of breakdowns.
Mean waiting time is part of the down time indicating the mean down-time lost in waiting
for materials or labour for attending to a break down
Increased mean waiting time will help the management in identifying the areas for
improvement such as organizing of trade force or improving the stores systems &
procedures or improving the spares parts control systems.
MAINTENANCE ORGANIZATION: The word organization is derived from the
organism which means an organized body with connected interdependent parts
sharing common life. Organization is a mechanism or structure which helps the
activities to be performed effectively.
Organization is the detailed arrangement of work and working condition in order to
perform the assigned activities in an effective manner.
Organization is the form of every human association for the attainment of a common
purpose.

Maintenance of modern equipment and industry requires a healthy, balanced and

rationalized organization devoted to achieve the goals of the maintenance task.
The basic objective of the maintenance organization is to ensure that the maintenance
functions are carried out effectively and hence to minimize the production loss due
to maintenance, maximization of profit, increase of market share & etc.
Three basic component of maintenance organization
1.Resources
2.Administration
3.Work planning and control system
RESOURCES: Resources included men, spares and tools involved in the task of
maintenance
ADMINISTRATION: Administration includes a hierarch of authority and responsibility
for making decision and plans the execution of the work.

WORKING PLANNING AND CONTROL SYSTEM: This is the mechanism for

planning and scheduling the work. This also includes the feed back of information to
derive the maintenance effort to its defined objectives.
Tasks of maintenance organization:
1.

Identification of organization roles pertaining to maintenance function

2.

Determination of maintenance work load

3.

Uniform distribution of
department

4.

Identification and assignment of essential works to the various sections of the

maintenance department

5.

Proper knowledge about the technical expertise/ experience of the workers deputed
for the particular job

6.

Proper training of the staff of maintenance to meet the growing demands of the
industry and to catch up with the modern trends in maintenance

total maintenance work to all the personal in the

7. Designing the policies and procedures at an early stage to help the maintenance
department to achieve the goals of the industry.

TYPES OF MAINTENANCE ORGANIZATION: The selection of a type of maintenance

system will largely depend on the structure of an industry.
1.Decentralized organizational structure:
In this type of organization, the maintenance is under the control of chief engineer
of production to ensure better understanding between production and maintenance
department
2.Centralized organizational structure:
In this type of organization, the maintenance is under the control of chief
maintenance engineer . The responsibilities and accountability is with the concerned
department heads

3.Partially centralized organizational structure: This is the modified version of

centralized maintenance organization and suitable for the industry where units are
located at for away locations. In this type, the maintenance personal attached with
production unit will carryout the routine maintenance works . Scheduled
maintenance works such as overhauls, planned maintenance work, procurement of
spare parts are under the control of chief maintenance engineer at the central office.
MAINTENANCE FUNCTIONS AND ACTIVITIES:
1.Identifying areas for implementation of preventive maintenance program
2.Making suitable arrangements for carrying out the maintenance work properly
3.Planning and scheduling the total maintenance work
4.Ensuring proper and timely supply of spare parts and tools required for the
maintenance
5.Standardization of maintenance work
6.Implementation modification to the existing equipment

7.Designing the systematic way for disposal

8.Identification of absolute and surplus equipment for replacement and disposal
9.Training of maintenance personnel
10.Analysis of future demands and forecast the role of maintenance activities
11.Implementation safety norms and procedures
12.Ensuring safety of personnel and equipment
MAINTENANCE ECONOMICS:
The cost of maintenance is difficult to measure due to random nature of failures. The
analysis of maintenance cost is helpful in taking a decision regarding replacement of
a machine or any of its components.
The maintenance cost consists of fixed cost and variable cost

MAINTENANCE ENGINEERING
Fixed cost: This includes the cost of support facilities including the maintenance staff
Variable cost: This includes the consumption of spare parts, replacement of components
cost of other facilities required to meet the requirement of maintenance.
MAINTENANCE BUDGET: The maintenance budget is used to set certain amount of
money to meet the expenditure incurred in achieving the objectives of maintenance.
1.Appropropriation Budget: Budget used to allocate money for each activity
independently
2.Fixed Budget: Fixed used to allocate money for a specified period of time
3. Variable Budget: Dynamic allocation of expenditure based on maintenance
requirement and activities.

Dr.T.Rajesh Kannah, Department of Mechanical Engineering

ANJALAI AMMAL-MAHALINGAM ENGINEERING COLLEGE,
KOVILVENNI-614 403.

MAINTENANCE ENGINEERING
FACTORS INVOLVED IN MAINTENANCE BUDGET:
1.

Data on failure, downtime cost due to equipment breakdown, cost of damage, loss of
production, penalty cost due to delay delivery, replacement cost spare parts and
material cost, wear and tear

2.

Proper judgment for replacing the machine instead of frequent repairs

3.

The cost involved in hiring the maintenance personal outside the organization to
carry out the specific tasks of maintenance needs

4.

Equipment overhaul schedule is to be carried out in time that will improve the
performance of equipment and many enhance its service life

5.

Expenses associated with fuel, oil, wages and maintenance of older machine

6.

Cost of additional manpower requirement for emergency breakdown and

maintenance

7.

Cost of man power involved

Dr.T.Rajesh Kannah, Department of Mechanical Engineering

ANJALAI AMMAL-MAHALINGAM ENGINEERING COLLEGE,
KOVILVENNI-614 403.

ESTIMATION OF ECONOMIC LIFE OF EQUIPMENT:

The economic life of equipment depends on the maintenance and repair cost, availability
and operational efficiency.

Operating hours
END OF THE FIRST UNIT
Dr.T.Rajesh Kannah, Department of Mechanical Engineering
ANJALAI AMMAL-MAHALINGAM ENGINEERING COLLEGE,
KOVILVENNI-614 403.