Maintenance management widescreen

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1 Slides presented By: SujeetPandit 1

Transcript of Maintenance management widescreen

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Slides presented By: Sujeet Pandit

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ContentsMaintenance management

Scope of Maintenance

Objectives

Impact of poor Maintenance

Areas of Maintenance

Maintenance Benefits

Condition Based Maintenance Decisions (CBM)

Types of Maintenance

Breakdown Maintenance

Preventive Maintenance

Predictive Maintenance

Routine Maintenance & Planned Maintenance

Maintenance Decisions

Maintenance Cost

Maintenance Cost Numerical

Total Productive Maintenance (TPM)

Numerical

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Maintenance Management

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The objective of maintenance is to maintain the capability of the system while controlling costs Maintenance is all activities involved in keeping a system’s

equipment in working order or operating condition Maintenance is concerned with avoiding or minimizing

downtime or to avoid undesirable results due to system failure.

Maintenance Management

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Scope of Maintenance

A) Primary Function:

a) Maintenance of existing plants & equipments.

b) Maintenance of existing plant buildings and grounds.

c) Equipment inspection and lubrication.

d) Utility generation and distribution.

e) Alterations to existing equipments and buildings.

f) New installations of equipments and buildings.

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Scope of Maintenance..contd…

B) Secondary Function:

a) Storekeeping (keeping stock of spares parts).

b) Plant protection including fire protection.

c) Waste disposal.

d) Salvage.

e) Insurance administration (against fire, theft, etc.).

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Objectives

• To increase functional reliability of production facilities.

• To enable product or service quality to be achieved through correctly adjustment, serviced and operated equipment.

• To maximize the useful life of the equipment.

• To minimize the total production or operating cost directly attributed to equipment service & repair.

• To minimize the frequency of interruptions to production by reducing breakdowns.

• To maximize the production capacity from the given equipment resources.

• To enhance the safety of manpower.

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Impact of Poor Maintenance

• Production capacity:

• Production costs:

• Product and service quality:

• Employee or customer safety:

• Customer satisfaction:

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Areas of maintenance management

• Civil Maintenance

• Mechanical maintenance

• Electrical Maintenance

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Maintenance Benefits

Maintenance

Reducedinventory

LowerOperating

costs

Faster, moreDependablethroughput

Improvedcapacity

Continuousimprovement

Improvedquality

Higherproductivity

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Condition Based Maintenance Decisions (CBM)

• To deduct the failures before they occurs.

• To carry out maintenance only when required.

• To reduce the maintenance costs and downtime costs.

Methodology of CBM• Proper identification and location of machines/equipment by

codification.

• Selection of critical machines and systems.

• Identifying components/elements.

• Fixing conditions parameters.

• Monitoring Techniques.

• Trend monitoring.

• Follow up.

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Types of maintenance

maintenance

Plannedmaintenance

Preventivemaintenance

Predictivemaintenance

Runningmaintenance

Shutdownmaintenance

Breakdownmaintenance

Routinemaintenance

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Breakdown Maintenance

Involves performing maintenance activities after a machine breakdown or malfunction has occurred and then must be repaired on an emergency or priority basis.

Breakdown maintenance includes repairs, replacement of parts or even overhaul to ensure the machine is put back in operating condition.

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Preventive Maintenance

Involves performing maintenance activities before the equipment fails.

Objectives are :

i) To reduce frequency and severity of interruptions to production caused by machine malfunctions.

ii) To detect potential problems earlier and avoid the associate cost.

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Preventive Maintenance – cont.

Preventive Maintenance activities includes regular inspection, machine adjustments, lubrication, cleaning and parts replacement

Two type of preventive maintenance

i) Routine maintenance

ii) Inspection

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Predictive maintenance

• This is a method in which the service life of important part is predicted based on inspection or diagnosis, in order to use the parts to the limit of their service life. Compared to periodic maintenance, predictive maintenance is condition based maintenance. It manages trend values, by measuring and analyzing data about deterioration and employs a surveillance system, designed to monitor conditions through an on-line system.

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Routine Maintenance & Planned Maintenance

• Ongoing maintenance activities such as cleaning washrooms, grading roads hand mowing lawns, which are required because of continuing use of the facilities.

Planned Maintenance

• There is only one reason to support a planned maintenance program. Planned maintenance increases profits.  The primary objective for any business is to produce profits for the owner.  Profit oriented goals apply to an elderly couple operating a corner grocery store, as well as to large corporations.  Even maintenance consulting firms have to operate at a profit. Maintenance control in a mine, fleet or plant can increase profits in two ways:

Increased production: Reduction of wasteful or unnecessary downtime increases production, thereby increasing profits.

Reduced costs: Higher productivity, method improvements or material changes can reduce maintenance costs, thereby increasing profits.

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How much preventive & breakdown maintenance Who performs maintenance

Centralized, decentralized, operator etc. Contract or in-house

When to replace or repair How much to replace

Individual or group replacement Spare parts inventory and standby machines.

Maintenance Decisions

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Maintenance Cost

Cost associated with maintenance are:

• Downtime (Idle time cost) cost due to equipment breakdown.

• Cost of spares or other material used for repairs.

• Cost of maintenance labour and overheads of maintenance departments.

• Losses due to inefficient operations of machines.

• Capital requirements required for replacement of machines.

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Cost

Amount of maintenance activity

Cost of breakdown maintenance

Cost of p

reventive m

aintenanceFix

ed Costs

M

Maintenance Costs

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Maintenance Cost ExampleShould the firm contract for maintenance on their printers?

Number of Breakdowns

Number of Months That Breakdowns Occurred

0 2

1 8

2 6

3 4

Total: 20

Average cost of breakdown = 300Use service contract - cost 150 per month and average breakdown is 1 per month.

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Maintenance Cost Example

1. Compute the expected number of breakdowns

Number of Breakdowns

Frequency Number of Breakdowns

Frequency

0 2/20 = .1 2 6/20 = .3

1 8/20 = .4 3 4/20 = .2

∑ Number of breakdowns

Expected number of breakdowns

Corresponding frequency= x

= (0)(.1) + (1)(.4) + (2)(.3) + (3)(.2)= 1.6 breakdowns per month

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Maintenance Cost Example

2. Compute the expected breakdown cost per month with no preventive maintenance

Expected breakdown cost

Expected number of breakdowns

Cost per breakdown= x

= (1.6)(300)= 480 per month

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Maintenance Cost Example

3. Compute the cost of preventive maintenance

Preventive maintenance cost

Cost of expected breakdowns if service contract signed

Cost of service contract

=

+

= (1 breakdown/month)(300) + 150/month= 450 per month

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Total Productive Maintenance (TPM)

Additional requirements of: Designing machines that are reliable, easy to operate

and easy to maintain. Emphasizing total cost of ownership when purchasing

machines, so that service and maintenance are included in the cost.

Developing preventive maintenance plans that utilize the best practices of operators, maintenance departments, and depot services.

Training workers to operate and maintain their own machines.

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Maintenance Performance Evaluation

1. Total Plant maintenance Productivity (TPMP) Plant output in a given period TPMP = Total maintenance cost in a given period time

Down Time Hours2. Down Time Index = *100

Production Hours Maintenance Cost

3. Maintenance Cost Index = *100Capital Cost

Hours the equipment ran at capacity4. Equipment Utilization =

Hours the equipment was available to run at Capacity during evaluation period

Total man power actually worked on the job5. Man Power Efficiency =

Total man hours scheduled for these work

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NumericalQ. PQR company has kept records of breakdowns of it’s machines for a 300

days work year as shown below:

No. of Breakdowns Frequency in days

01234

40150703010

300

The firm estimates that each breakdown cost Rs.650/- and is considering adopting aPreventing maintenance program which would cost Rs.200 per day and limit theNumber of breakdown to an average of one per day . What is the expected annualSaving from preventing maintenance program?

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SolutionTo determine the expected number of breakdowns per year:

No. of breakdowns (x) Frequency of Bds in days.f(x)

Probability distribution of Bds P(x)

Expected value of Bds. X.P(x)

01234

40150703010

40/300=0.133150/300=0.50070/300=0.23330/300=0.10010/300=0.033

Nil0.5000.4660.3000.132

Total 300 1.000 1.400

Total number of breakdowns per day = 1.400Cost of breakdown per day = 1.40 * 650 = Rs.910/-Cost of preventing maintenance programmed per day

= Rs.200 + Rs.650 = Rs.850/-Expected annual savings from the preventing maintenance program

= (910 – 850) * 300 days = Rs.18,000

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