ENGG ZC242

Maintenance & Safety

BITS Pilani
Pilani Campus

Anil Jindal
Department of Mechanical Engineering

BITS Pilani
Pilani Campus

Introduction to Maintenance
Systems
Chapter 1, Lecture-1

Learning Objectives
Course Handout
Definitions of Maintenance
History of Maintenance
Maintenance Objectives/Scope and Benefits/Policies

BITS Pilani, Pilani Campus

Course Description
Objectives, Functions, and Types of maintenance
Defect due to wear, lubrication, maintenance of different
equipments and their elements
Management of maintenance function, spares planning,
overhauling and TPM
Safety and safety management, environmental safety,
chemical safety, occupational health management,
control of major industrial hazards, managing
emergencies, employee participation in safety and HRD
for maintenance and safety.

BITS Pilani, Pilani Campus

Scope and Objectives

The objective of the course is to make students
understand the concepts of maintenance and safety
and their importance in industry.
The course deals with the planning and control of
various maintenance engineering.
The learning of the basic and recent trends in
maintenance engineering will help the students in their
professional life. The safety portion the course will
enable the students to deal with effectively the various
types of hazard in industry.

BITS Pilani, Pilani Campus

Prescribed Text Book

K.

Venkataraman,

Maintenance

Engineering

and

Management, Prentice Hall of India, 2007.

BITS Pilani, Pilani Campus

Reference Books
R1

Mishra R.C. & K. Pathak, Maintenance Engineering and

Management, Prentice-Hall of India., 2002

R2

Sushil Kumar Srivastava, Industrial Maintenance Management, S.

Chand & Company, 2002.
Krishnan N.V., Safety Management in Industry, Jaico Publishing
House, 1993.
L M Deshmukh, Industrial Safety Management, TMH, 2006.

R3
R4
R5

Charles E. Ebeling: An introduction to Reliability and

maintainability engineering, edition
2000, Fourteen reprint 2011, TMH, New Delhi

BITS Pilani, Pilani Campus

Reference 247 e-Books

www.books24x7.com
Maintenance

Management:

Its

Auditing

and

Benchmarking: In Search of Maintenance Management

Excellence by Anthony Kelly , Industrial Press 2006
(336 pages) Citation
Total Productive Maintenance

by Terry Wireman ,

Industrial Press 2004 (204 pages)

BITS Pilani, Pilani Campus

Plan of Study - I
Week No. Chapter Name

Objective/Topic

Introduction to Maintenance Systems

Maintainability

Maintenance as Business Proposition,

T1-Chapter 1
Maintenance Philosophy, Types of
Maintenance systems
Measure of maintainability, Methods of T1-Chapter 2
Evaluation of Maintainability, Design for
Maintainability

3-4

Condition-Based Maintenance (CBM)

5-6

Reliability Centred Maintenance (RCM) Reliability being active and standby,

FMECA, RCFA, Criticality analysis
Asset management function, EOQ, 2-Bin
Asset and Spare Parts Management
system of material procurement,
computing
Maintenance Lubricants and Their
Applications
Key Definitions in Lubrication

Improvement effectiveness thru CBM,

various CBM techniques

Reference to
Text Books

T1-Chapter 3

T1-Chapter 4
T1-Chapter 5

Appendix I
Appendix II

Syllabus for Mid- Semester Test (Closed Book): Topics in Week No. 1 to 9

BITS Pilani, Pilani Campus

Plan of Study - II
Week No.

Chapter Name

Objective/Topic

Reliability

10

Safety Engineering and Fault Tree Analysis

Determination of reliability of
Reference Book 5
different systems: Serial
Configuration, parallel Configuration
and Combined Series-parallel systems
Hazard analysis, , General rules in fire T1-Chapter 6
hazard and safety, Faulty tree analysis

11

Total Productive Maintenance

12

Maintenance Planning and Scheduling

13

Computer Applications in Maintenance

Management

CMMS, data acquisition, software

failure, software security

T1-Chapter 9

14

Statistical Distribution in Preventive

Maintenance

T1-Chapter 10

15

Maintenance Integration

Types of distributions, Normal

distribution, Gamma distribution,
Binomial distribution etc.
Steps of integration, future trends

16

Maintenance Effectiveness

Reference to Text
Books

Methodology, Origin, Implementation, T1-Chapter 7

Lean Maintenance, Training and
monitoring
Maintenance planning, Shutdown
T1-Chapter 8
planning and execution

T1-Chapter 11

Elements of effectiveness,
T1-Chapter 12
Presentation of data, OEE, Agility etc.

Syllabus for Comprehensive Exam (Open Book): All topics given in plan of study (I & II)
BITS Pilani, Pilani Campus

Evaluation Scheme
EC
No.

Evaluation
Duration
Component &
Type of Examination
EC-1 Quiz
--

Weightage

Day, Date,
Session,Time

15%

--

EC-2 Mid-Semester Test

(Closed Book)*

2 Hours

35%

20/09/2015 (AN)
2 PM TO 4 PM

EC-3 Comprehensive
Exam
(Open Book)*

3 Hours

50%

08/11/2015 (AN)
2 PM TO 5 PM

BITS Pilani, Pilani Campus

Evaluation Scheme (EC-1 Quiz)

EC-1 No.

Syllabus

Weightage

To be
administered
online during

Quiz 1

Chapter 1-3

5%

August 20-30, 2015

Quiz 2

Chapter 4-6,
Appendix I & II

5%

September 20-30,
2015

Quiz 3

Chapter 7-12

5%

October 20-30,
2015

BITS Pilani, Pilani Campus

Nature of Exam
Closed Book Test: No reference material of any kind will
be permitted inside the exam hall.
Open Book Exam: Use of any printed / written reference
material (books and notebooks) will be permitted inside
the exam hall. Loose sheets of paper will not be
permitted. Computers of any kind will not be allowed
inside the exam hall. Use of calculators will be allowed in
all exams. No exchange of any material will be allowed.

BITS Pilani, Pilani Campus

Note
It shall be the responsibility of the individual student to be regular in
maintaining the self study schedule as given in the course handout, attend
the online/on demand lectures as per details that would be put up in the
BITS LMS Taxila website www.taxila.bits-pilani.ac.in and take all the
prescribed components of the evaluation such as Assignment (Course Page
on LMS Taxila), Mid Semester Test and Comprehensive Examination
according to the Evaluation Scheme given in the respective Course Handout.
If the student is unable to appear for the Regular Test/Examination due to
genuine exigencies, the student must refer to the procedure for applying for
Make-up Test/Examination, which will be available through the Important
Information link on the BITS WILP website on the date of the Regular
Test/Examination.
The Make-up Tests/Exams will be conducted only at selected exam centers
on the dates to be announced later.
BITS Pilani, Pilani Campus

BITS Pilani
Pilani Campus

Introduction to Maintenance
Systems
Chapter - 1

What is Maintenance?
Maintenance is an age old function which developed &
progressed, knowingly or unknowingly, along with the
operation of equipments

Maintenance refers to all the activities which assist in

keeping plant & equipment in good condition.
Any

activity

such

as

tests,

measurements,

replacements, adjustments and repair, intended to

restore or retain a functional unit in a specified state in

which the unit can perform its required functions.

BITS Pilani, Pilani Campus

What is Maintenance?
Maintenance is not merely preventive maintenance,
although this aspect is an important ingredient.
Maintenance is not lubrication, although lubrication is
one of its primary functions.
Maintenance is not simply a frenetic rush to repair a
broken machine part or building segment, although this
is more often than not the dominant maintenance
activity.

BITS Pilani, Pilani Campus

What is Maintenance?
Maintenance is a science since its execution relies,
sooner or later, on most or all of the sciences.
It is an art because seemingly identical problems
regularly demand and receive varying approaches and
actions and because some managers, foremen, and
mechanics display greater aptitude for it than others
show or even attain.
It is above all a philosophy because it is a discipline
that can be applied depending upon a wide range of
variables that frequently transcend more immediate and
obvious solutions.
BITS Pilani, Pilani Campus

Maintenance Definition
All actions which have the objective of retaining or restoring
an item in or to a state in which it can perform its required
function. The actions include the combination of all technical
and
corresponding
administrative,
managerial,
and
supervision actions
Maintenance can also be defined as a set of activities that
ensure any physical asset to continue to fulfill its intended
functions to the standard of performance desired by the user.

Repair & Maintenance

Is fixing or setting things all right for any sort of mechanical or
electrical devices if the same gets out of the order or broken
down as well as performing the routine actions which keep the
device in working order or prevent trouble from arising.
BITS Pilani, Pilani Campus

History of Maintenance
Pre 1945):

Reactive
Corrective

1945-1970:

Reactive,
Preventive,
Condition monitoring,
Proactive

1970-1980:

Reactive,
Preventive,
Condition monitoring,
Proactive

1990s:

Reactive, Preventive,
Condition monitoring, Proactive
TPM, RCM
BITS Pilani, Pilani Campus

Purpose of Maintenance
To reduce the business risks
Immediate reaction to emergencies and over-power
problems
To support the end user during various scenarios of a
devices life cycle be it configuration, commissioning,
parameterization, diagnosis, repair, firmware update,
asset management, audit training etc.
Well defined uniform parameters and rules should
enable the manufacturer to offer devices that behave in
a uniform manner and that should enable the end user to
act quickly.

BITS Pilani, Pilani Campus

Maintenance Functions
To get a smooth, reliable and cost effective maintenance in
a company, different departments/functions in the company
has to be coordinated and not only the maintenance
department alone.
It affects the economical, technical and organizational
nature of a system.
Earlier the objective of maintenance function was
considered to optimize plant availability at minimum cost.
Today it is being considered as, Maintenance affects all
aspects of business effectiveness, safety, energy efficiency,
product quality, customer service, environment and not just
the plant availability at minimum cost.

BITS Pilani, Pilani Campus

Maintenance Functions
Maintenance functions can be grouped in two categories: Basic functions
Composite functions

BITS Pilani, Pilani Campus

Basic Functions
Replace: To remove the unserviceable item and install a
serviceable counterpart.
Repair: to indentify the troubles and restore serviceability by
corrective action.
Overhaul To restore an item to a completely operational
condition as required by maintenance standard in appropriate
technical publications.
Rebuild Action necessary for the restoration of
unserviceable equipment to a like new condition in
accordance with original manufacturing standards.
Service/ lubricate introduction of lubricant to sliding surfaces
to reduce friction and wear.
Inspect/check- to compare the physical, mechanical or
electrical characteristics with standards through examination.
BITS Pilani, Pilani Campus

Basic Functions
Test
Adjust To maintain, within prescribed limits, by bringing
into proper or exact position, or by setting the operating
characteristics to specified parameters.
Align To adjust specified variable elements of an item to
bring about optimum or desired performance.
Calibrate- To determine and cause corrections to be made
or adjusted, on instruments or test, measuring equipment
used in precision measurement.
Measure
Winding
Install the act of fixing an item in an manner to allow
proper working.
BITS Pilani, Pilani Campus

Composite Functions
Protecting the building, structures and plants/factories
Reducing downtimes and increasing equipment
availability, also helping in increasing equipment
utilization
Analyze repetitive failure and arrange their elimination
Forecast maintenance spares, tools and consumables
and help their procurement and inventory management
Controlling and directing labour forces
Economy in maintenance department
Maximizing utilization of available resources

BITS Pilani, Pilani Campus

Composite Functions
Ensuring
safety
of
installation
and
reducing
environmental pollution
Cost reduction and cost control
Preparing maintenance budgets
Waste reduction and waste recovery
Improving technical communication
Training of maintenance personnel on related jobs etc

BITS Pilani, Pilani Campus

Maintenance Functions
This is an another way of classifying the maintenance function is:
Primary Functions
Maintenance of existing plant equipment
Maintenance of existing plant buildings and grounds
Equipment inspection and lubrication
Utilities generation and distribution
Alterations and new installations
Secondary Functions
Storekeeping
Plant protection
Waste disposal
Salvage
Insurance
Other services
BITS Pilani, Pilani Campus

Maintenance Levels
Classification of Maintenance Levels:
Time for maintenance ( duration of maintenance)
Frequency of maintenance ( Daily, Weekly, Monthly etc)
Quality of maintenance
Organizational level :- Daily servicing, maintenance
checks, inspections for condition, exchange of
components etc.
Intermediate level :- Repairs on/off the equipment,
extended periodical inspections
BITS Pilani, Pilani Campus

Maintenance Objectives
Maintenance purposes, functions, objectives and responsibilities are
interrelated and are over-lapped to some extent. Some objectives of
maintenance can be:

Operational

Maximum operating efficiency of plant

Maximum availability of plant
High Quality performance
Safety
To maintain a plant clean & good appearance
To extend Plant life to the last limit
To reduce environmental impact due to machinery etc
To provide service that will avert all breakdowns at all times at any cost.

Cost
Minimize maintenance expenditure and maximize profits
To provide activities with in the limits of budgetary control
BITS Pilani, Pilani Campus

Maintenance Benefits
Financial
Organizational
Technical
Human
Customer relations

BITS Pilani, Pilani Campus

Maintenance Benefits
Financial Benefits
Extended Plant Life
Uninterrupted production
Improved quality of production
Reduced production delays
Reduced cost of repairs

BITS Pilani, Pilani Campus

Maintenance Benefits
Organizational Benefits
Co-ordination between production and maintenance
Man power planning
Planning of deliveries

BITS Pilani, Pilani Campus

Maintenance Benefits
Technical Benefits
Improved equipment suitability
Build up of technical data
Improved maintenance schedules
Improved plant condition

BITS Pilani, Pilani Campus

Maintenance Benefits
Human considerations Benefits
Increased Safety
Improved House keeping
Less friction between relationships

BITS Pilani, Pilani Campus

Maintenance Benefits
Customer relationship Benefits

Reliable delivery calls

Show case house keeping

BITS Pilani, Pilani Campus

Maintenance Policy
Scope and limits of maintenance
Type and level of service expected
Responsibilities to management
Personal Practices
Trade union contracts
Budget and financial controls

BITS Pilani, Pilani Campus

What does maintenance really

do?
Repair, lubrication, overhaul, inspection, replacement of
parts
Training of the maintenance staff
Training of the production staff
Testing parts for suitability
Planning of servicing schedules
Improvement and modifications of plant
Production of spare parts

BITS Pilani, Pilani Campus

Maintenance System of Today

Protecting the buildings, structures and plants.
Increase equipment availability & reducing
downtime.
Controlling & directing labour forces.
Economy in maintenance department.
Maximum utilization of available resources.
Preparing maintenance budgets.
Emphasis on waste recovery.
Improving technical communication.
Preventing waste of tools, spare and other materials.

BITS Pilani, Pilani Campus

For achieving these objectives various

control functions & actions are to be taken
which would be discussed in subsequent
chapters.

BITS Pilani, Pilani Campus

Thanks

BITS Pilani, Pilani Campus