R&D Maintenance

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MAINTENANCEENGINEERING

Muhammad Sajid

Department of chemical engineering, UOG

Research & development in maintenance

Role of overhauling in maintenance

Expert system in maintenance

Note: Data in this presentation

is taken from different books

and is used only foreducational purpose. Credit


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Research and Development in

Maintenance


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Areas Need Improvements

Influence of maintenance on design andselection of plants.

Use of available information.

Training requirements. Standardization of products.

Spare parts management

Development o maintenance facilities.

Concept of condition based maintenance. Concept of contract maintenance.

Development of indigenous spare parts.


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Areas Need

Improvements(Cont.)

Influence of maintenance on design and

selection of plants.The necessity and importance of maintenance can be decided by the designer,

manufacturer and users in consultation with each other in order to improve theavailability and reliability of equipment/system. The sole aim here should be to keep

the operating and maintenance costs to minimum.

Use of available information.The information available on maintainability, reliability etc. can be used to improve the

performance of the equipment/system


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(Cont.)

Training requirements.

The time to time training must be imparted to the practicing engineers and technicians

to make full use of the advancements in technology.

Standardization of products.

Efforts should be make for the standardization of the parts/components particularly

when they are imported, so that the users face minimum problems.

Interchangeability of parts must be given due attention to make its use feasible.


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(Cont.)

Spare parts management

The availability of spare parts is the main concern of the maintenance engineers and

the determination of its quantity is a difficult task. Therefore, efforts should be make

to use the facilities of experts in the field.

Development o maintenance facilities.

The advancement in technology have made the task of the maintenance engineers

more challenging because of the size and the volume of the equipment/system .

For effective working of maintenance groups, special facilities required must be

developed to face the challenges in the field of maintenance.


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(Cont.)

Concept of condition based maintenance.Attempt should be make to use the modern techniques in the

field of maintenance in the case of costly and sophisticated

equipment/system. This concept is quite new and helpful in

maintaining machinery effectively. Although the initial cost ismore but better availability and safety of the equipment is

assured.

Concept of contract maintenance.

As maintenance is complex in nature and required someexpertise. With regard to specialized system/equipment the

contract maintenance works well since qualified and trained

personnel are engaged in the job. e.g. computer industry


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(Cont.)

Development of indigenous spare parts.

In case of imported equipments/systems it isdifficult to procure and preserve adequate

quantity of spare parts and therefore effortsshould be made to develop material and spareparts at the organizational level. Sometimesthe manufacturers stop production of a

particular type of equipment the sameequipment is n use. Obsolescence is anotherfactor, which calls for the development oftechnology to meet out the challenges.


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Role of Overhauling

Equipment/systems are of two types

I. Equipment with diminishing efficiency

II. Equipment with constant efficiency

Overhauling of first type of equipments, reduces

its operational costs and extended its life

span.

The period of overhaul must be decided toactually derive the gain of the above concept.


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Expert System in Maintenance

The unexpected equipment failure entail

significant financial losses in manufacturing

system.

In order to avoid unscheduled failure, theconcept of preventive maintenance with expert

system can be used.

An expert system is a program, which has awide base of knowledge in a restricted

domain, and uses complex inferential

reasoning to perform tasks, which human

experts could do.


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Expert System in Maintenance(Cont.)

Knowledge Base:

It encompasses knowledge about the domain

problem. Knowledge representing methods

are production rules, frames, semantic netsand predicate logic.

Inference engine:

The inference engine is the problem solvingcontrol strategy or rule interpreter, which

applies the knowledge in the knowledge base

of the problem. The strategies are forward and

backward chaining.


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External Maintenance

When maintenance within organization is not

possible or maintenance system required

some specific expertise then task given to

external group of experts. This is calledexternal maintenance.

External maintenance is also called

outsourcing.

Many companies such as DESCON, EITMAD

and FFC provide such specific services.

Computer industry is a major outsourcing

industry.


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Logistics


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Finance Management


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Inventory Management


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Effects of Maintenance

Cost effective maintenance will boost theproductivity of the production system.

Optimum maintenance will prolong the life of

equipments/system. Helpful in achieving production target and

continuous plant operation.

Effective maintenance will enhance the

reliability of the system/equipment. Proper maintenance will improve the working

environment


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Maintainability

Maintainability is defined as the probability ofrestoration of a failed device or equipment or

asset to operational effectiveness within a

specified time.

It is associated to the design of assets to be

maintained and is the measure of the ease of

maintenance.

Maintainability is expressed as mean time torepair (MTTR) i.e. how much time is required to

restore the equipment/system to its working

condition

The limitation of maintainability are- it cannot be


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Reliability

It is defined as the probability that an asset or

a system will operate satisfactorily for a pre-

determined period of time, under the working

conditions for which it was designed. Failure Rate (FR) or mean time between

failure (MTBF) is a parameter to express

reliability.


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Principles of Maintenance

Effectiveness of maintenance depends on

systematic conductance of various interrelated

activities. To achieve the overall objectives of a

maintenance system, certain establishedprinciples must be followed. These principles

help guide the maintenance staff in the

efficient discharge of their duties.


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Plant Management in Maintenance

Work

The main role of maintenance function is toprovide safe and effective operation ofproduction equipment in order to achieve thedesired production targets on timeeconomically. Sometimes it is observed thatuntil and unless there is breakdown ofequipment, the production department doesnot follow the maintenance programmebecause of its keenness to accomplish the jobin stipulated time. Therefore it is necessarythat all the departments cooperate with eachother to meet the organizational goals.


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Maintenance Objective Versus

Plant Production

The plant production department is normallyassigned production targets, in the light ofwhich the maintenance team must formulateits assigned objectives to match the totalobjectives of the organization. It is observedthat, in practice, the production departmenttends to overlook the maintenance functions inits eagerness to meet the production targets.Such an attitude may lead to seriouscircumstances, resulting in equipment failuresor accidents. The programme of scheduledmaintenance must be followed.


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Establishment of Work-order and

Recording System

Preparation of work order for maintenance

activity is an important task as it indicates the

nature of the work to be performed and the

series of operations to be followed for aparticular job. It is essential that at every

workstation, proper records/entries be

maintained to monitor the health of the

equipment as well as its lifespan. Presently, inmany organization this task is being performed

with the help of computers.


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Information Based Decision

Making

Effective and reliable information system is

essential for the successful execution of any

activity. Such a system may be used for

decision making in respect of manpower andspare parts requirements there fore data

entries for any type of breakdown must be

properly recorded in time, so that the same

may be utilized as and when required.


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Adherence to Planned

Maintenance System

1. Lack of implementation of manufacturer

instruction during operation/maintenance.

2. Result is unscheduled breakdown

3. Proper implementation of manufacturer

instruction results longer life and safe

operation

4. Proper use of manpower

Pl i f M i


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Planning of Maintenance

Functions

Major jobs must be planned for effective use of

resources.

After breakdown cost analysis and

comparisons must be done. Efficiency analysis of every major maintenance

activity.

Planning of un excepted breakdown/un evenrepairs.


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Manpower for Maintenance


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Work Force Control

As the nature of maintenance work is quite

unpredictable, the cost of maintenance

function can be kept under control only with

proper monitoring of the work force. For this purpose field data must be collected

regularly, accurately and completely.


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Quality and Availability of Spare

Parts

At the time of purchase of an equipment the

manufacturer do supply some spare parts, but

these are usually not sufficient for all types offaults and for whole life of equipments.

It is essential to stock a complete range and scale

of genuine spare parts to sustain the

functionalities of the equipment without safety

hazards.

T i i f M i t


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Training of Maintenance

Workforce

As equipment changing to modern and

sophisticated, the nature of maintenance also

needs changes.

Whenever a new equipment is purchased, themaintenance personnel along with the operating

personnel must be trained.

Supervisory staff also required proper training for

effective supervision and quality of maintenance.

On job training and evaluation of training is also

essential to meet growing challenges of

maintaining sophisticated and delicate

equipments.


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R&D Maintenance

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