Project Management- Topic 1

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Topic 1

Introduction to Maintenance

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m s

Maintenance goal

Terothecnology

Importance of Planned Maintenance

Maintenance and Support costs

Changing world of maintenance Challenges facing maintenance

Basic Maintenance concept

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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 function.

Nor is maintenance simply a frantic rush to repaira broken machine parts or building segment,although this can sometimes be a dominantmaintenance activity.

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Maintenance

The term MAINTENANCE,

covers all activities undertaken to keepequipment in a particular condition or return

it to such condition.

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Maintenance Managementmeans

The management of maintenance

It indicates a comprehensivemanagement, from planning to their

maintenance.

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Modern maintenance management is notto repair broken equipment rapidly

BUT

Modern maintenance management is tokeep the equipment running at high

capacity and produce quality productsat the lowest cost possible

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Maintenance GoalThe goal of any well-run maintenanceorganization is to have the lowest cost of

the sum of two quantities, i.e.: Maintenance labour and material: and

Production loss (which includes lack of abilityto produce, and value added material that islost as a result of a break down) reductionresulting from an inadequate maintenanceprogram

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TerotechnologyDefinition:

A combination of management,financial, engineering and otherpractices applied to physical assets inpursuit of economic life cycle costs. Life

Cycle Costing (LCC) involves collectingall the cost information incurred duringplant life

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Terotechnologysystem

Typical contributions include:

Design - assets designed formaintainability and reliability

Procurement - application of 'best buy'procurement techniques

Projects - provision of assets havingoperability and maintainability features

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Terotechnology

system (cont.) Operations - introduction of operating

techniques which reduce downtime and

improve care of assets Finance - cost control, cost monitoring

and feedback

Personnel - selection and trainingprogrammes for operating andmaintenance personnel

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Importance of Planned

Maintenance

Equipment is subject to deterioration, causingmalfunction and breakdown with the effects:

Reducing productive capability by reducingoutput due to downtime

Increasing operating cost

Interfering customer service

Affects to maintain product quality standards Has serious safety and environmentconsequence

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Maintenance and Support

costs Loss of production or service

Maintenance personnel

Education and training

Replacement

Repair parts Spares

Consumables

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Maintenance and Support costs(cont.)

Workshop installation

Facilities

Tools and test equipment

Planning system

Programs

Manuals & documentation

Inventory costs

Pack, handle, store and transport

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Changing world ofmaintenance

Growing expectations ofmaintenance

Changing views onequipment failure

New maintenancetechniques

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Challenges facingmaintenance

To select the most appropriate techniques

To deal with each type of failure process.

To fulfill all the expectations of the owners ofthe assets, the users of the assets and ofsociety as a whole

In the most cost-effective and enduring fashion

With the active support and co-operation of allthe people involved

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Effective management ofmaintenance function

Ensure equipment be available tofunction efficiently when needed

Consistent with safety of people andplant

Contribute to the production and profitobjectives

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Basic Maintenance Concept

Any actions carried out to retain an itemin,

or restore

it to, an acceptable condition

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(1) Service: the supply of necessary machineservice and support

Lubricate

Inspect

Adjust, calibrate, align, rig Replace

Repair

Cleaning Remove

Install

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(1) Service: the supply of necessary machineservice and support (cont.)

Functional test

Preserve or de-preserve Fault isolation

Handling

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(2) Logistic: the supply of materials, sparesand personnel for service andmaintenance.

(3) Maintenance strategy planning: theselection of maintenance and repairstrategies to minimize life cycle cost.

(4) Failure analysis: for design and reliabilityimprovement