MAINTENANCE management

The Business School, Kashmir University

Group members: Younis Bhat (group leader) Hinan Bhat Towseef Wani Zoya Fayaz Rasikha Andrabi Sabha Khan Obera Khan Nadia Khan

Introduction Maintenance Costs Maintenance policies for Facilities Procedure For Maintenance Preventive v/s Breakdown maintenance Total productive maintenance(TPM) Introduction and benefits of TPM Trends In Maintenance

Content

Younis(410) Nadia Khan (409) Obera (451) Hinan(427) Rasikha (445) Towseef wani(408) Sabha Khan() Zoya

MAINTENANCE?

What is Maintenance?
MAINTENANCE
The term maintenance covers all Activities undertaken to keep equipment in a Particular condition or return It to such condition
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History of Maintenance
Historically, maintenance activities have been regarded as a necessary evil by the various management functions in an organization. The evolution of maintenance can be traced from the days prior to World War II. The attitude of the managers then was to fix the equipment when it breaks. The period after World War II saw the introduction of the word terotechnology

Maintenance Management
All the activities of the management that determine the maintenance objectives or priorities strategies and responsibilities and implement them by means such as maintenance planning, maintenance control and supervision, and several improving methods including economical aspects in the organization."

Why??? maintenance mgt

Production Capacity Production Costs Product and service quality Employee satisfaction Customer Satisfaction

Functions of Maintenance Management

Organizing Maintenance Resources
Directing Execution Of Maintenance Plan

Maintenance Planning

Maintenance Management

Initiate Corrective actions if schedule slips

Minimizing Maintenance Costs

Define Process for Performing Maintenance

Types of Maintenance

Zoya Khan ()

Types of Maintenance
Reactive Maintenance. Corrective maintenance. Preventive maintenance. Predictive maintenance. Reliability-Centered Maintenance (RCM). Maintenance software: CMMS and AMS.

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Reactive Maintenance
Run-to-failure approach: letting a system run until something breaks. Maximum cost in terms of revenue lost and equipment replacement.

Corrective maintenance.

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Corrective maintenance.
Maintenance task performed to identify, isolate, and rectify a fault so that the failed equipment, machine, or system can be restored to an operational condition within the tolerances or limits established for in-service operations. Example: Lubricate motors when they become noisy or vibrations occur.

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Preventive maintenance.

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Preventive maintenance.
Programmed maintenance which is carried out in order to prevent the Occurrence of failures before they Develop to a breakdown or Interruption in production. Example: Lubricate pumps every 2,000 hours.

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Predictive maintenance.

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Predictive maintenance.
Monitoring and measuring the condition of the assets to determine whether they will fail during some future period and then taking appropriate action to avoid the consequences of that failure. Example: Conduct scans on pumps and panels to determine if and when work is required.

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Reliability-Centered Maintenance (RCM).

Prioritizing maintenance efforts based on equipments importance to operations, its downtime cost in revenue and customer loss, its impact on safety, and its cost of repair.

Maintenance software: CMMS and AMS.

Most facilities practicing predictive maintenance purchase or develop a specialized database, commonly referred to as either an asset management system (AMS) or a computer managed maintenance system (CMMS).

Finding the Right

Maintenance Mix
Corrective Maintenance (CM) 40% of the assets Preventative Maintenance (PM) 50% of the assets Predictive Maintenance (PdM) 10% of the assets

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8/3/2012

Contd
Description Maintenance Strategy Clean the roof drains when Corrective Maintenance (CM) there is ponded water on the roof. Clean the roof drains quarterly. Preventive Maintenance (PM) on a fixed-interval Clean the roof drains after each Preventative (PM) on variablerainfall and more frequently interval during the fall season. Review data from the roof leak Predictive maintenance (PdM) detection system and clean the drains as required.

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Maintenance costs

Nadia Khan (409)

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Maintenance costs

Types of maintenance costs

Direct maintenance cost

Indirect maintenance cost

Cost curve
Annual Cost Minimum Total Maintenance Cost

Minimum Level Of Preventive Maintenance Degree of Preventive Maintenance

Maintenance efficiency
Maintenance is not measured by the cost incurred on it. Its efficiency is related to the production output.

How to measure maintenance efficiency

PM factor method: PM factor = prime production/main cost 1000

Example
Should the firm contract for maintenance of its printers or not????
No of breakdowns 0 No of months breakdowns occurred 2

1
2 3

8
6 4 20

Average cost of breakdown= $300 No of breakdowns if service is contracted =1 Cost of service per month = $150

Computed expected no of breakdowns

No of breakdowns
0 1 2 3 Frequency of breakdowns 2/20=0.1 8/20=0.4 6/20=0.3 4/20=0.2 20

Expected no. of breakdowns = {no of breakdowns corresponding frequency} (00.1)+(10.4)+(20.3)+(30.2)=1.6

Expected breakdown cost with no preventive maintenance =1.6300=$480 per month cost of preventive maintenance:
Cost of expected breakdown + cost of service ,

if service is contracted {1breakdown p.m} =$300+$150p.m= $450p.m Therefore, the firm should hire maintenance services.

Maintenance Policies For Facilities

Obera Khan ()

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Maintenance Policies For Facilities

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8/3/2012

Maintenance Policies For Facilities

Maintenance Departments are usually split into two groups: a) Building and Ground maintenance deptt. b) Equipment maintenance deptt. Building & Ground can include workers such as electricians,welders,pipefitters,steamfitters,painters,gl aziers,carpenters,millwrights,janitors and ground keepers It is the responsibility of the Building & Ground group to maintain the appearance and functional utility of all buildings, lawns, planting areas, parking lots, fences & 33 all other facilities from the interior of the building to the perimeter of the grounds.

 The equipment maintenance group can include such workers as mechanics , machinists , welders, oilers, electricians , instrument calibrators and electronic technicians. It is responsibility of equipment maintenance group to provide equipment repair crews , shops for repairing equipment, and the appropriate level of preventive maintenance for equipments.

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Contd
Enhancing Preventive Maintenance Providing Extra Machines Replacing parts as early as possible Training Operators regarding Machine Care Enhancing & Simplifying the capability of Maintenance Dept Overdesigning Production Machines Involving Operators in repair Increasing the supply of spare parts & standby machines.

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Maintenance Procedure

Hinan Bhat (427)

General principles
The following aspects should be considered with respect to Maintenance Procedures: Human factors; Poorly skilled work force; Unconscious and conscious incompetence; Good maintainability principles; Knowledge of failure rate and maintainability; and Clear criteria for recognition of faults and 37 marginal performance.

Predictive maintenance steps

Setup. Test. Monitor. Repair.

Preventive v/s Breakdown maintenance

Syed Rasikha Andrabi (445)

Preventive maintenance
It is a set of activities that are performed on plant equipment, machinery, and systems before the occurrence of a failure in order to protect them and to prevent or eliminate any degradation in their operating conditions

Breakdown maintenance
In this type, actions such as repair, replacement, or restore will be carried out after the occurrence of a failure in order to eliminate the source of this failure or reduce the frequency of its occurrence.

Preventive v/s Breakdown maintenance

Preventive Maintenance Principle Prevention is better than cure Locates weak spots of machinery and equipments Provides them periodic/scheduled inspections and minor repairs to reduce the danger of unanticipated breakdowns Breakdown Maintenance Focus is on repairing (cure) Locates the spoilt and damaged spots to be corrected Works directly on repairing rather than inspecting first

Preventive Maintenance

Reduces break down and thereby down time

Greater safety of workers Better product quality and fewer reworks and scraps. Faster production and increased output Increases plant life

Breakdown Maintenance Breakdown generally occurs inappropriate times leading to poor and hurried maintenance Increases chances of accidents and less safety for both workers and machines Excessive delay in production & reduces output Faster plant deterioration

Preventive Maintenance Lower maintenance and repair costs Its activities include: Replacements adjustments major overhauls inspections and, lubrications

Breakdown Maintenance Higher costs are incurred during breakdown maintenance Its maintenance activities involves: Fault detection Fault isolation Fault elimination Verification of fault elimination.

Preventive maintenance is further divided into:

Routine maintenance Running maintenance Opportunity maintenance Window maintenance Shutdown preventive maintenance

Breakdown maintenance is further divided into:

Deferred maintenance Shutdown corrective maintenance Remedial maintenance

Total productive maintenance (TPM)

Towseef Wani (408)

Overview
A Japanese concept that originated in 1971 as a method for improved machine availability through better utilization of resources. Here operations are enable to understand and identify potential problems righting them before they can impact production One way to think of TPM is deterioration prevention.

Motive
Zero error Zero work related accidents Zero loss

Goal
Continuously improve all operational conditions within a production system by stimulating daily awareness of its employees

TPM will increase productivity in an organization where :A clear business culture is designed to continuously improve the efficiency of the total production system A standardized and systematic approach is used, where all losses are prevented and/or known. All departments, influencing productivity, will be involved to move from a reactive- to a predictive mind-set A transparent multidisciplinary organization is reaching zero losses Steps are taken as a journey, not as a quick menu

Eight Pillars Of TPM

Focused improvement (kobetsu kaizen) Autonomous maintenance (jishu hozen) Planned maintenance Training & education Early phase management Quality maintenance (Hinshitsu hozen) Office TPM Safety, health & environment

BASE OF TPM
Seiri (sorting out the required or not required item) Seition (systematic arrangement of required items) Seiso (cleanliness) Seiketsu (standardization) Shitsuke (self discipline)

Introduction of TPM in an organization:

Sabha Showket (421)

Introduction of TPM in an organization:

Steps involved: PREPARATORY STAGE:
This stage involves following steps: Announcement by Management to all about TPM introduction in the organization. Initial education and propaganda for TPM. Setting up TPM and departmental committees Establishing the TPM working system and target A master plan for institutionalizing

INTRODUCTION STAGE: IMPLEMENTATION: INSTITUTIONALISING STAGE:

Benefits of TPM:
Productivity Improvement. Quality Improvement. Cost Reduction. Employee Ownership. Employee Confidence. Improved working environment. Customer Satisfaction. Increased Plant Reliability. Improved workforce skills . Improved relationships between maintenance.

operations

and

Drawbacks
Two main reasons: Insufficient knowledge and skill. Long duration.

Conclusion