MAINTENANCE MAINTENANCE MANAGEMENTMANAGEMENT

Submitted Submitted to:-to:-

Dr. Mini Dr. Mini SekharanSekharan

Submitted by:- Swapnil chatterjee 3rd sem, SIF, CUSAT

INTRODUCTIONINTRODUCTION The design life of each equipments The design life of each equipments

requires periodic maintenance.requires periodic maintenance. The objectives of maintenance The objectives of maintenance

management are ---management are --- To maintain the equipments in its best To maintain the equipments in its best

operating condition with economical cost.operating condition with economical cost. Extending the life of the equipment to its Extending the life of the equipment to its

design.design. Types of Maintenance Management are Types of Maintenance Management are

------ Breakdown or Reactive Maintenance, Breakdown or Reactive Maintenance, Preventive Maintenance and Preventive Maintenance and Predictive Maintenance.Predictive Maintenance.

Reactive MaintenanceReactive Maintenance Run it till it breaks Maintenance Run it till it breaks Maintenance Mode.Mode.Advantages:---Advantages:--- Low investment cost for Maintenance.Low investment cost for Maintenance. Less staff is required.Less staff is required.

Dis--advantages:---Dis--advantages:--- In-efficient use of staff.In-efficient use of staff. Waiting for the equipment to break is responsible for Waiting for the equipment to break is responsible for

shortening of the life of the equipment causes more shortening of the life of the equipment causes more frequent replacement with high replacement cost.frequent replacement with high replacement cost.

To repair the critical piece of equipment and to bring it in To repair the critical piece of equipment and to bring it in action very quickly, the maintenance overtime cost action very quickly, the maintenance overtime cost occurs.occurs.

Primary equipment damage due to absence of Preventive Primary equipment damage due to absence of Preventive Maintenance causes also Secondary equipment or Process Maintenance causes also Secondary equipment or Process damage ensuring more additional costs.damage ensuring more additional costs.

Preventive MaintenancePreventive Maintenance Actions performed on a time or machine run based Actions performed on a time or machine run based

schedule that detect, preclude or mitigate degradation of schedule that detect, preclude or mitigate degradation of a component or system with the aim of sustaining or a component or system with the aim of sustaining or extending its useful life through controlling degradation extending its useful life through controlling degradation to an acceptable level.to an acceptable level.

Advantages:-Advantages:- Equipment life is Equipment life is

extended and its extended and its reliability increased.reliability increased.

Energy savings.Energy savings. 12%-18% cost 12%-18% cost

savings over Reactive savings over Reactive Maintenance Maintenance program.program.

Dis-advantages:-Dis-advantages:- Catastrophic failures Catastrophic failures

still likely to occur.still likely to occur. Performance of Performance of

unneeded unneeded Maintenance.Maintenance.

Potential for incidental Potential for incidental damage to components damage to components in conducting in conducting unneeded unneeded Maintenance.Maintenance.

Predictive MaintenancePredictive Maintenance Measurements that detects the onset of a degradation Measurements that detects the onset of a degradation

mechanism, thereby allowing casual stressors to be mechanism, thereby allowing casual stressors to be eliminated or controlled prior to any significant eliminated or controlled prior to any significant deterioration in the component physical state.deterioration in the component physical state.

Predictive Maintenance differs from the Preventive Predictive Maintenance differs from the Preventive Maintenance based on the Maintenance need on the Maintenance based on the Maintenance need on the actual condition of machine rather than on some pre-set actual condition of machine rather than on some pre-set schedule.schedule.

Advantages:-Advantages:- Increased component life.Increased component life. Decrease in costs for parts Decrease in costs for parts

and labour.and labour. Better product quality.Better product quality. Energy savings.Energy savings. Improved worker and Improved worker and

environmental safety.environmental safety. Estimated 8%-12% cost Estimated 8%-12% cost

savings over Preventive savings over Preventive Maintenance program.Maintenance program.

Dis-advantages:-Dis-advantages:-

Increased Increased investment in staff investment in staff training.training.

Savings potential Savings potential not readily seen by not readily seen by management.management.

Maintenance PlanningMaintenance Planning

Maintenance Planning is done to find Maintenance Planning is done to find the answer of What & how is the job the answer of What & how is the job and where the job is to be done.and where the job is to be done.

It is depended on the Efficiency and It is depended on the Efficiency and Cost of action.Cost of action.

Persons involved in Maintenance Persons involved in Maintenance Planning should have the Knowledge Planning should have the Knowledge about jobs, about jobs,

Steps of Maintenance Steps of Maintenance PlanningPlanning

The main steps to be followed for proper Maintenance The main steps to be followed for proper Maintenance Planning are --------Planning are --------

Knowledge Base:-Knowledge Base:- It includes knowledge about It includes knowledge about equipment, job, available techniques, materials and equipment, job, available techniques, materials and facilities.facilities.

Job Investigation at the site:-Job Investigation at the site:-It gives the clear It gives the clear perception of the total jobs.perception of the total jobs.

Identify and Document the work:-Identify and Document the work:-Knowing the earlier Knowing the earlier two steps and knowing the needs of Preventive , Predictive two steps and knowing the needs of Preventive , Predictive and other Maintenance jobs.and other Maintenance jobs.

Development of repair plan:-Development of repair plan:-Preparation of step by Preparation of step by step procedures which would accomplish the work with the step procedures which would accomplish the work with the most economical use of time, manpower and material.most economical use of time, manpower and material.

Preparation tools and facilities listPreparation tools and facilities list indicating the indicating the needs of special tools, tackles and facilities needed.needs of special tools, tackles and facilities needed.

Estimation of time required to do the jobEstimation of time required to do the job with work with work measurement technique and critical path analysis.measurement technique and critical path analysis.

Maintenance SchedulingMaintenance Scheduling

Scheduling is the function of Scheduling is the function of coordinating all of the logistical issue coordinating all of the logistical issue around the issues regarding the around the issues regarding the execution phase of work.execution phase of work.