Maintenance Engineering Part I

Maintenance Engineering-Part I : Maintenance Engineering-Part I S Nandha Kumar

Contents : Contents Introduction Introduction to the concept of planning Long Range Planning Short Range Planning Immediate Activity Planning Maintenance Planning Objectives of Maintenance Planning Factors to be considered Types of maintenance Why Maintenance Management? Tasks of Maintenance Organization

Introduction : Introduction Maintenance is the routine and recurring process of keeping a particular machine or asset in its normal operating condition so that it can deliver the expected performance or service without any loss or damage. The responsibility of the maintenance function is to ensure that production equipment/facilities are available for use for maximum time at minimum cost within stipulated time period

Introduction to concept of Planning : Introduction to concept of Planning Planning ensures the smooth operation of the system. For effective working of any system, it is necessary to plan and schedule its activities. Classification: Long Range Planning Short Range Planning Planning for immediate activity Maintenance Planning

Introduction to concept of Planning : Introduction to concept of Planning Long Range Planning Long range planning refers to the planning spread over span of five to ten years. Strategies are developed and operational programs are devised for the period of planning. Short Range Planning Prepared relatively for a short period of time say one to two years. Immediate Activity Planning Done at the working levels when required Maintenance Planning Assigning jobs to the maintenance crew. Must tackle the emergency maintenance as well as to ensure the maintenance workforce is fully utilized.

of Maintenance Planning : of Maintenance Planning Minimum break down and keep the plant in working condition Ensuring availability of machines ad services Keep machines and other facilities in condition to improve profits Right time delivery to the customers To keep maintenance cost as low as possible Providing trained supervision Improved quality Increase profits Job simplification

Factors to be considered : Factors to be considered Job Distribution Dividing the job to small jobs and later combining it to get the complete work. Programme Selection of Activities Determination of frequency of maintenance Decision of cost effective methodology Man power allocation To execute various jobs Skilled worker allocation

Factors to be considered : Factors to be considered Staffing Provides the manpower for maintenance Planning Techniques To develop the overall master plan Gannt charts, Milestone method, Critical Plan method Planning Procedures Organizing maintenance resources Scheduling the resources Execution of plans Establishing a feedback system

Factors to be considered : Factors to be considered Estimation of maintenance work Determine the quality of maintenance work Previous records are to be analyzed for estimation Maintenance Control Auditing to ensure effective utilization of maintenance budget

Types of maintenance : Types of maintenance Breakdown Maintenance Planned Maintenance Preventive Maintenance Corrective Maintenance Predictive Maintenance Condition Based Maintenance

Why Maintenance Management : Why Maintenance Management Minimization of downtime Improvement in availability of system Extended life of equipment Safety and smooth operation of process Provide adequate backup supply Minimization of normal expected wear and tear of equipment Safety of the personal involved in the organization Increased reliability of the system Provide proper working environment Cost effective maintenance

Tasks of Maintenance Organization : Tasks of Maintenance Organization Identification of organization goals Determination of maintenance workloads Uniform distribution of total maintenance work Assigning various works to various departments Proper Knowledge about the techniques involved Proper Training Planning and scheduling of maintenance work Implementing modifications Assisting the purchase department in buying goods Ensuring proper and timely supply of spare parts Implementation of safety norms and procedures Analysis of future demands and forecast the role of maintenance activities

Topics in the Part II : Topics in the Part II Types of Maintenance Organization Maintenance Cost Maintenance Budget Total Productive Maintenance Maintenance Scheduling Some Repair Method Basic Repair Cycle Thank You