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• Maintenance management science is still misunderstood by many

• Plant maintenance is one of the most challenging businesses.
• The development in the manufacturing industry has maturated
• Each year billions of dollars are spent on equipment maintenance
around the world.
• Each year over $300 billion are spent on plant maintenance and
operations by U.S. industry,(Engineering Maintenance by Dhillon).
• The operation and maintenance budget request of the U.S.
department of defense for fiscal year 1997 was on the order of $79
• Maintenance was considered “a necessary evil”.
• How maintenance can be controlled and managed?

• Nowadays, maintenance is part of the production process.
• Maintenance function is normally a secondary function
for the company production.
• The function of maintenance is to maintain the capacity
of the production function.

Production Demand for

Capacity maintenance
Primary production input

The relationship between maintenance function and production function

Maintenance Definition
• Maintenance can be defined as the service provided by a
certain entity to assure the availability of production capacity
to satisfy the demands.
• Maintenance systems are responsible for keeping equipment
fit, safe to operate and well configured to perform its task.

Maintenance Purpose and Objectives.

• To increase the equipment utilization by reducing downtime.
• To increase primary process capability.
• To improve primary process performance such as quality,
profit, etc…
• To satisfy regulatory requirements, such as safety, hazards
and environmental standards in a cost effective manner.
Max. operation


Operation Installation Manufacturing Technical Machines

Specification Design
Installation Feedback

Maintenance Maintenance Feedback


Feedback about installation , operation and maintenance

‫‪Burn-in period‬‬
‫إعطاب مبكرة‬
‫معدل التاكل‬ ‫( اخطاء تصميم‬
‫إعطاب عرضية (تشغيل في وجود‬ ‫إعطاب إجهاد (تأكل وتقدم في العمر)‬
‫‪Failure rate‬‬ ‫‪،‬تركيب‪ ،‬تشغيل)‬ ‫صيانة) ‪Useful life period‬‬ ‫نقطة االنهيار‬
‫‪A‬‬ ‫‪D‬‬

‫‪B‬‬ ‫‪C‬‬
‫‪Normal operation‬‬

‫الشكل يوضح العالقة بين عمر اآللة ومعدل التآكل‬ ‫عمر اآللة‬

Necessary Maintenance Activities
• Determining needed resources (manpower, spares, tools and
• Scheduling;
• Monitoring job progress;
• Ensuring quality of completed jobs;
• Feedback and continuous improvement.

Maintenance Planning and Scheduling.
• Planning is probably the most critical factor in the success of
a maintenance department;
• Planning and scheduling are usually compressed into one
title. However, they are two different functions:
 Planning is the core activity that gathers the information from all other
parties and generates a harmony;
 The schedule determines when a job should be done, scheduling
functions are:
 Manpower, which has also to be sub-classified according to skills available;
 Materials, which include spare parts;
 Tools and equipment, which are necessary to perform various maintenance
 Facilities, which are needed to perform the maintenance tasks;
 Planning and scheduling work orders;
 Estimating costs.

Maintenance Types and Classification
• (Maintenance types are two):
Planed maintenance and.
An-planed maintenance.
• Maintenance may be classified into four categories):
Breakdown maintenance.
Preventive maintenance (PM).
Predictive (Condition-Based) maintenance (CBM).
Proactive maintenance. (RBM)

Maintenance Engineering.
 Different predictive maintenance methods and techniques
such as vibration monitoring, using time and frequency
domains have been developed to detect and diagnose faults,
improving maintenance and, hence, the performance of both
machines and systems;
 Early detection and diagnosis machines when the faults are
less serious, not only provides information about the nature
of the problem but also allows maintenance personnel to
plan the necessary corrective action, and production losses
can be minimised;
 Such an approach will result in lower labour and parts
costs, less downtime and more efficient use of maintenance

Why Monitor and Diagnose Faults in Machines?
Even minor faults can contribute to a reduction in the
useful life of high-cost machines and it is in the self-interest
of companies to avoid such potentially unnecessary losses.
Faults not only directly reduce the performance of a
machine, they can also cause secondary damage to other
parts of the machine;
 This can lead to significant economic loss for the user and
in some cases personal injury

Maintenance Management: Is the management of all
assets owned by a company, based on maximizing the
return on investment in the asset (Wireman, 1998).
The purpose of maintenance management is to reduce
the adverse effects of breakdown and to maximize the
facility availability at minimum cost. (Lofsten, 1999).

The reasons to manage the process of maintenance:
• Managing maintenance will reduce long-term costs;
• Maintenance management will help meeting a competitive
• Maintenance management will help preserve your physical