Maintenance Management

Maintenance management

Contents Concept Importance Objectives Types of maintenance Total Productive maintenance(TPM)

ConceptTwo categories of maintenance activities in a firm are :i. Maintaining buildings, parking lots,

lawns, fences, services and utilities.

ii. Maintaining equipments, machinery, material handling equipments, transport vehicles, tools, test instruments, office equipments, etc.

Maintenance: It is the function of production management that is concerned with the day-to-day problem of keeping the physical plant in good operating condition.

Maintenance Management: It is concerned with the direction and organization of resources in order to control the availability and performance of the industrial plants to some specified level.

It involves maintenance planning,maintenance scheduling,execution of maintenance activities, and controlling costs of maintenance.

Maintenance covers two broad categories of functions :

Primary functionsSecondary functions

Primary functions Maintenance of existing plant and equipments. Maintenance of existing plant building and

grounds. Equipment inspection and lubrication Utilities generation and distribution. Alternatives to existing equipments and

buildings. New installations of equipments and buildings.

Secondary functions Storekeeping Plant protection including fire protection Waste disposal Salvage Insurance administration Janitorial services Property accounting Pollution and noise abatement or control Any other service delegated to maintenance

by plant management

Importance of maintenance management Equipments must be kept in reliable condition without

costly work stoppage and down time due to repairs if the company is to remain productive and competitive.

Quality assurance Market share improvement Cost control Equipment failure will be disastrous for such

companies. They need proper maintenance to maintain equipment in good condition.

Impact of Poor maintenance Production capacity

Production costs

Product and service quality

Employee or Customer safety

Customer satisfaction

objectives1. Minimizing the loss of productive time because of

equipment failure(i.e. minimizing idle time of equipment due to break down).

2. Minimizing the repair time and repair cost.3. Minimizing the loss due to production stoppages4. Efficient use of maintenance personnel and equipments5. Prolonging the life of capital assets by minimizing the

rate of wear and tear6. To keep all productive assets in good working condition.7. To maximize efficiency and economy in production

through optimum use of facilities.8. To minimize accidents through regular inspection and

repair of safety devices

9. To minimize the total maintenance cost which includes the cost of repair, cost of preventive maintenance and inventory carrying costs due to spare parts inventory

10. To improve the quality of products and to improve productivity.

Types of Maintenance1. Break down maintenance or Corrective

maintenance

2. Preventive maintenance

3. Predictive maintenance

4. Routine maintenance

5. Planned Maintenance

Break down maintenance or Corrective maintenance

As the name suggests, corrective maintenance occurs when there is a work stoppage because of machine breakdown or fail and must be repaired on urgent basis.

Corrective maintenance seeks to achieve the following objectives To get equipment back into operation as quickly as

possible to minimize interruption to production.

To control the cost of repairing.

To control the investment in replacement spare parts that are used when machines are repaired.

To perform the a appropriate amount of repairs at each malfunction.

Preventive maintenance Preventive maintenance is undertaken before the need

arises(i.e. machine or equipments fail) and aims to minimize the possibility of unanticipated production interruptions or major breakdowns.

It consists of Proper design and installation equipments Periodic inspection of plant and equipment Repetitive servicing, upkeep and overhaul of

equipment Adequate lubrication, cleaning and painting of

buildings and equipment.

A well-conceived preventive maintenance programme should contain the following features:

1. Proper identification of all items to be included in the programme.

2. Adequate records covering volume of work, cost and so forth.

3. Inspection on define schedule4. Use of checklist by inspectors5. Well qualified inspectors 6. Use of repair budgets for major items of equipment7. Administrative procedures that provide necessary

fulfillment and follow-up on programme.

7. Maintenance action(inspection

report)

1.Job identification or

preparation of facility register

2. Preventive maintenance

schedule

3. Machine history record

4. Job specification

5. Preventive maintenance Programme

8. maintenance request

9. Corrective and control action

6. Preventive maintenance

schedule(weekly, monthly)

Benefits of Preventive maintenance Greater safety for workers Decreased production downtime Fewer large scale and repetitive repairs Less cost for simple repairs made before

breakdown Less standby equipment required Better spare parts control Lower unit cost of manufacturer

Predictive maintenance It is modern approach to preventive

maintenance using sensitive instruments to predict anticipated failure of machines and equipments

Routine maintenance This includes activities such as periodic inspection,

cleaning, lubrication and repair of equipments after their service life.

1. Running Maintenance Maintenance work is carried out while the equipment is in the operating condition.

e.g. greasing or lubricating the bearing while machine is running

2. Shut down maintenanceMaintenance work is carried out while the equipment is out of service.e.g. Repairing boiler tubes of a boiler.

Planned Maintenance Here, maintenance activities are carried out

according to a predetermined schedule.

It is also called as scheduled maintenance or productive maintenance.

It aims to reduce machine stoppage due to sudden breakdowns necessitating emergency maintenance.