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8/10/2019 Maintanance Mgm Ppt
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DR. MAHADEO GHADGE
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What is Maintenance
• The activity carried out to prevent theoccurrence of failure and activitycarried out after failure to rectify the
defect is called maintenance.
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Why Maintenance Required
• Plant and machines in anyorganisation is expected to runcontinuously without any interruption
during the production period.• Interruptions are frequently felt on
account of machine break downs dueto failures of machine parts /components.
• There is always some loss ofproduction on account of machine
failure.
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C USES OF F ILURE OF M CHINES
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Down Time
• The duration by which any machine goesout of production due to break down iscalled down time.
• The down time is the total time taken on
account of maintenance to rectify the fault.• The total time taken on account of
maintenance involves the time actuallyspent by the respective maintenance team
to correct the fault and waiting time forwant of spares required for rectify thedefect.
• Down time = Repair time + waiting time
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Waiting Time
• The waiting time is the mostunproductive elements of total downtime . The reason for waiting time
could be :-
• Want of spares
• Want of crew members
• Lack of communication.
• Lack of proper supervision
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Mean Time Between Failure( MTBF)
• This is the average time a machinecan operate without the occurrence ofany failure.
• MTBF indicates the operationalreliability of the machine. Higher thevalue of MTBF, higher will be the
operational reliability of the machinebecause of lesser number of failures.
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Mean Time Between Failure( MTBF)
• To improve the operational reliability ,the number of failures should bereduced. Failures can be reduced if
the machines are maintained properlywith adequate care and attention.
• Failures can reduce by better
maintenance.
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OBJECTIVES OF PP
Continuous increase in the production through
improved overhauling of machines in a plantat scheduled intervals.
Eliminating any risk of accidents in the plant
that might be cause of a machine breakdown.Proper maintenance of machines & their parts
to prevent & decrease the wear & tear of
machines & their parts.Through examination of the machines against
their productivity & accuracy level.
Minimizing plant shut down time.
OBJECTIVES OF MAINTENANCE
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Maintenance
Corrective Preventive
Unplanned Planned
Break Down Correct/Rectify
Faults
Indirect Direct
Conditioning
MonitoringCleaning
Lubricating
Replacement
Overhauling
Failure Reports
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PREVENTIVE MAINTENANCE• Machines are checked much in advance of any kind of
failures.
• Checklists are developed for each equipment or machineso that machine parts are checked for any incipientproblems.
• Once the problem is identified in advance, the required
corrective action is taken before the machine stopsfunctioning.
• Different behavior of various machine parts encounterdifferent problems at different frequencies.
• Some parts should be checked in each shift; others maybe checked once a day, a month, in three months, in six
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CORRECTIVE MAINTENANCE
•
During preventive maintenance checks, certainproblems are noticed about the condition of themachine. The machine may be operating in a conditionthat may cause damage to the machine if continued tooperate. Therefore the machine is to be stopped with
out delay to correct the situation.• The corrective action taken after the checks under
preventive maintenance is termed as correctivemaintenance.
• Similarly, condition-monitoring checks may reveal thatthe machine has lots of vibrations.
• The steps for correcting the situation are termed ascorrective maintenance.
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BREAKDOWN MAINTENANCE
• The sudden stoppage of a machine due tosome failure or problem is termed asbreakdown of the machine.
• In some organizations, machines are attendedonly when the machine has stoppedfunctioning.
• The maintenance carried out in this manner iscalled breakdown maintenance.
• In breakdown maintenance, repair andcorrective action is taken up when the problemhas actually cropped up.
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Inspection maintenance Lubrication Maintenance
Cleaning maintenance
Record Maintenance Spare part maintenance
Service maintenance
Emergency maintenance
Maintenance training
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The worn out or deteriorated machine part The machine part with corrosion (rust)
Loosely held nut or bold in machine
Improper alignment Defect in machine due to overheating
As soon as defects are identified , the
corrective action should be taken Inspection can be internal and external
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Proper & regular lubrication help in reducingrate of wearing and tearing of machine. Toensure good lubrication following activitiesare often required
Identifying right part
Cleaning of oil tank
Replacing
Lubricating Scheduling the frequency of lubrication
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Cleaning is done to remove unwanted thingsor dust witch affect badly performance ofmachine or tools.
Cleaning of transformer or resistor
Electrical fuses
Filters.
Motor Fan blades
Oil tank