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Anil Jindal
Department of Mechanical Engineering
BITS Pilani
Pilani Campus
Introduction to Maintenance
Systems
Chapter 1, Lecture -2
Learning Objectives
Maintenance Objectives/Scope and Benefits/Policies
Maintenance as Business Proposition
Maintenance Philosophy
Types of Maintenance Systems
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Maintenance Objectives
Operational
Cost
Minimize maintenance expenditure and maximize profits
To provide activities with in the limits of budgetary control
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Maintenance Benefits
Financial
Organizational
Technical
Human
Customer relations
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Financial Benefits
Extended Plant Life
Uninterrupted production
Improved quality of production
Reduced production delays
Reduced cost of repairs
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Organizational Benefits
Co-ordination between production and maintenance
Man power planning
Planning of deliveries
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Technical Benefits
Improved equipment suitability
Build up of technical data
Improved maintenance schedules
Improved plant condition
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Human considerations
Benefits
Increased Safety
Improved House keeping
Less friction between relationships
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Customer relationship
Benefits
Reliable delivery calls
Show case house keeping
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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
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Maintenance Functions
Primary Functions
Secondary Functions
Storekeeping
Plant protection
Waste disposal
Salvage
Insurance
Other services
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Maintenance as Business
Proposition
The maintenance costs continue to capture the attention
of senior management as the investment as reliability in
assets become increasingly greater.
In some companies, maintenance cost is becoming a
larger percentage of total cost.
For example, a company recently identified maintenance
cost as in excess of 40 percent of their total cost of
conversion,
representing
significant
scope
for
improvement.
Hence it is essential to run maintenance as business.
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Automation
Huge leap in automation in last two decades.
The number of operators have shrunk and the machines
are taking over.
Incase of some systems there are no operators.
Computer programs drive these systems with occasional
additional guidance from people in distant control room.
More machines replacing men means, more
maintenance activities.
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Maintenance Philosophy
Most people think of the maintenance function as:
o
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Values in improving
maintenance practices
Without planning and scheduling, resources are primarily
in reactive mode and are only 30 to 40 percent effective.
Loading resources by planning and scheduling on daily
basis can increase the effectiveness to over 60
percent.
Program Driven Maintenance(PDM) increases the OEE
(Overall Equipment Efficiency) significantly.
Moving to PDM approach yields up to 40 percent
decrease in maintenance cost.
Human stress levels are dramatically reduced.
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Planned Maintenance
It includes concepts of essential care, fixed time
maintenance and condition monitoring.
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Planned Maintenance
Essential Care(EC): This includes preventing failures
from occurring with tasks such as detailed cleaning,
lubrication, alignment, balancing, operating procedures,
adjustments, and installation procedures.
Fixed-Time Maintenance(FTM): It constitutes all
replacements that are done on a fixed schedule
regardless of condition, e.g. programmed replacements
and overhauls
Condition monitoring(CM): It constitutes all inspections
from simple subjective tasks such as look, listen, feel,
smell etc. to objective tasks such as vibration analysis,
oil-sampling, ultrasonic leak detection, pressure checks,
current readings etc.
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Preventive Maintenance
It is a planned maintenance of plant and equipment to
improve equipment life and to prevent unplanned
maintenance activity.
To minimize breakdown and excessive depreciation.
It can include
o Non destructive testing
o Periodic inspection like checking the lubricant level in engine.
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Preventive Maintenance
Programme Risks
Damage to an adjacent equipment during a PM task.
Damage to the equipment receiving the PM task.
Damage during the performance of an inspection,
repair, adjustment or installation of a replacement part.
Installing material that is defective, incorrectly installing
a replacement part or incorrectly reassembling material.
Reintroducing infant mortality by installing new parts or
materials.
Damage due to an error in reinstalling equipment into its
original location.
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Preventive Maintenance
Execution
Traditionally it was based on concept of
bathtub cure.
Bathtub curve has 3 stage
o Infant mortality stage
o Fairly long run stage
o Wear out stage
Preventive Maintenance
Program
Identify the critical equipments
List the subsystems and parts for the identified
equipments
Determine the preventive maintenance procedure for
each of the subsystem and parts
Prepare a details work instruction for each procedure
Fix the frequency for each activity
Prepare a PM Calendar for the plant
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Preventive Maintenance
Bush bearing
Roller / Ball bearing
Gear assembly
Belt & Pulley
Chain & Sprocket
Key
Spline
Clutch
Lead-screw & Nut
Coolant system
Lubrication system
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Predictive Maintenance
The condition of the equipment or machinery is predicted
by observing the signals it emits based on which the
maintenance action is taken
This maintenance is also called condition monitoring
The monitoring can be done online or offline
Some of the technologies that can be used to predict the
condition are
o
o
o
o
Vibration measurement
Thermography for measurement of heat
Oil an lubrication monitoring
Ultrasonic methods for leak detection, etc.
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Predictive Maintenance
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Proactive Maintenance
If a disease is pinpointed and eliminated long before any
symptoms occur in your body, it would save your money
in doctor bills and keep you out of hospital in the long
run.
Proactive maintenance commissions corrective action
aimed at the source of failure.
Main difference between predictive and condition based
maintenance is that condition based maintenance uses
predicting tools long before the failure occurs and
predetermined intervals.
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Summary
Comment on the following statements
Maintenance is a necessary evil
Maintenance is a bottomless pit for expenses
Thanks
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