BITS PilaniPilani Campus

Assessment Of Maintenance Management System

Submitted by:Sagar Kumar sharma

BITS Pilani, Pilani Campus

Maintenance Definition

Maintenance Management Objectives.

Maintenance History

Maintenance Procedures

Maintenance Policies & Strategies.

Maintenance Planning & Scheduling.

Nature and General classification of maintenance problem

Maintenance Cost Control.

Work Order System.

Spare Part Control.

Reliability Centered Maintenance

Total Productive Maintenance.

Performance Keys Indicators.

Content

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

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BITS Pilani, Pilani Campus

Maintenance Definition

British Standard Glossary of terms (3811:1993) defined maintenance as:

“The combination of all technical and administrative actions, including supervision actions, intended to retain an item in, or restore it to, a state in which it can perform a required function”.

Maintenance is a set of organised activities that are carried out in order to keep an item in its best operational condition with minimum cost acquired.

BITS Pilani, Pilani Campus

Modern maintenance management is not to repair broken equipment rapidly. Modern maintenance management is to keep the equipment running at high capacity and produce quality products at lowest cost possible.

There are many reasons why maintenance is becoming more and more important. In developing countries , where many old machines are operating, the spare part problem are arising. Some times it is difficult to find spare parts for equipment and if it is possible to find them, they are usually very expensive and must be paid on foreign currency.

Due to long lead times of supply of spares, it is common that the spare part inventory is growing bigger than necessary. A very essential part in maintenance management is developing countries to reduce the need of spare parts, as well as to maintain the minimum level of shock to save foreign currency, but still keeping the productivity high.

Why Maintenance Management

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Basic functions of a maintenance management system

1. Preventive maintenance2. Plant and unit record(Equipment)3. Inventory and spare parts control system, Purchasing system4. Document record5. Planning system for maintenance and work order routines6. Technical/economic analysis of plant history, maintenance and machine

availability

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Organizing the Maintenance Function

Centralized maintenance department Does all maintenance (PM & breakdown)

Decentralized Maintenance department Useful if different equipment used in different areas of company

Contract maintenance Used if little equipment or expertise

Operator ownership approach

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Operator-Ownership Approach

Operator does preventive maintenance Equipment condition is their responsibility Learns equipment better Increases worker’s pride Reduces repair time & PM costs

Maintenance department is backup Handles non-routine problems Provides maintenance training Has plant-wide responsibilities

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

The Basic Maintenance Cycle

PLANNING

PERFORMANCE

RECORDING

ANALYSIS

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Maintenance Planning & Scheduling

Planning:• Management surveys show that the average productivity of

maintenance employees is between 25 and 35%.• This means that a craftsman has less than 4 hours of productive

time per 8-hour day due to poor maintenance management.

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Maintenance Planning & Scheduling

The following are some of the most common wastes of productive time:-

• Waiting for instructions• Looking for supervisors• Checking out the job• Multiple trips to the stores• No special tools• Waiting for approval• Too many craft workers per job• Insufficient workers scheduled for the job.• Incomplete planning & communications• Waiting for equipment to be shutdown• Waiting for drawings from engineering

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Maintenance Planning & Scheduling

On the average, 2 hours are lost every time worker is pulled off a job for any reason.

To prevent this major loss of productivity, it is necessary to implement some form of job

planning function.

The concept of job planning is to determine what is to be done and how it is to be done.

Job planning consists of two main areas:

1. Craft skills

2. Material required for the job.

These labor and material requirements may be converted to dollars to give an estimate

of the cost of completing the work order.

BITS Pilani, Pilani Campus

Planning

Maintenance Planning & Scheduling

Planning can be accomplished by the supervisor if there are relatively few maintenance

personnel.

If there are more than 20 craftsmen, planning is best done by separate maintenance

planners, otherwise the foremen have a tendency to do paperwork when they could

more profitably spend their time in supervising and directing the work of the craftsmen.

BITS Pilani, Pilani Campus

Type of Work to be planned:– Emergency maintenance and critical maintenance (work needed

immediately or within 24 hours) is seldom planned. – These request are of short duration and are performed so quickly that there

is no time to plan them. – These types of work orders should not be considered in planning functions– Normal corrective or routine work orders should be the primary consideration

of the planning function.– These work orders are received and placed in work backlog.– As the workforce and materials become available to carry out the work, it is

scheduled.– Included in this type of work are preventive and predictive maintenance work

orders.

Maintenance Planning & Scheduling

BITS Pilani, Pilani Campus

Type of Work to be planned:

• The other group of work requests that can be planned are the shutdown,

turnaround, or the outage work orders.

• For this type of work, it is important that the equipment be shut down and

overhauled in the shortest possible time.

• Only by accurate estimating and scheduling of these work requests can the

shutdown be successful.

Maintenance Planning & Scheduling

BITS Pilani, Pilani Campus

How to Plan Maintenance Work :

– Effective planning requires the planners to be skilled and knowledgeable in the craft area they

are planning; therefore, supervisors or top craftsmen will make the best planners.

– If an inexperienced individual is promoted to planner, the results of the planning program will

not be satisfactory. Instead of increasing productivity, you may find productivity decreasing.

– The planning begins once the work order is approved by management.

– It is then assigned to the planner, who carefully studies the job.

– The planner must decide the following:-

The crafts required,

The time required,

The materials required, and

Whether outside help in the form specialists, contractors, or special rental equipment is

required.

Maintenance Planning & Scheduling

BITS Pilani, Pilani Campus

How to Plan Maintenance Work :– When the planner is deciding on the required crafts, he must also decide not only the

number of craftsmen, but also the skill level required.– The time estimate for work order is important. If there is no time estimate, you will never

know the man-hours of work that is in the crafts backlog. Without this information, you can never accurately determine the proper staffing levels for your plant.

– The material required for the work order will determine whether it can be scheduled.– If the necessary materials are not available and the work order is scheduled, the

craftsmen will lose productivity looking for the spare parts and waiting for supervisor to find them work that can be performed.

– It is also necessary to plan the materials so that an accurate estimate of the cost of the work order can be obtained.

– The miscellaneous items to be planned are important to proper completion of the work order.

– If special skills are required from outside source, the in-house craftsmen may not be able to complete the work order quickly or with necessary quality.

Maintenance Planning & Scheduling

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Maintenance Planning & Scheduling

Scheduling Indicators:

Within a maintenance strategy, you can use different scheduling indicators to specify the type of scheduling you require or to define a cycle set: Time-based (for example, every 30 days) Time-based by key date (for example, every 30

days on the 30th day of the month) Time-based by factory calendar (for example, every

30 working days) Performance-based (for example, every 50

operating hours)

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Benefits of Planning Maintenance

Long term plans insight Decision making support Optimizing connectivity among operation and maintenance

departments Figuring out areas of cost reduction Training areas and needs

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Nature of maintenance problem

Maintenance can be classifies as follow1. General classification of maintenance

problems1. Mechanical Failure2. Thermal Failure3. Chemical Failure

2. Classification of maintenance problem based on time span1. Short Run Maintenance Problem2. Long Run Maintenance Problem

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

General classification Maintenance problem

Mechanical Failure Worn out bushes and bearings and other moving parts. Fatigue of machine members Creep of material at high temp Excessive forced vibration, misalignments etc.

Thermal Failure Overheating of the component Lack of lubrication Inadequate of cooling Electrical insulation failure

Chemical Failure Highly corrosive fluids containing abrasive particles Failure of protective linings like glass , rubber etc.

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Classification maintenance problem based on time span

Short run production problem

Maintenance problem which are carried out in a sort period of time are known as short run production system. It may be hourly, daily ,weekly and monthly.

Example:-

Hourly- inspection of correct lubricant, level of coolant, sharpness of cutting tool.

Daily- cleaning of m/c, tightening of nuts, correct cooling, inspection of various indicators, minor adjustment of parts.

Weekly- Major adjustment, lubrication, tightening of parts.

Monthly- checking for insulation, corrosion, safety guards, checking of worn-out and distorted parts.

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Maintenance Cost Control

Objectives of Maintenance and Maintenance Cost

During the years the maintenance function has not been seen as a condition for production output. The previous approach has been that maintenance is the necessary evil, one among the cost generators in the organization. Very often the maintenance strategy in plants has been to reduce the maintenance cost as much as possible without thinking of the consequences.Objective of the maintenance is , as priority one , to create an availability performance which is suitable for production demands in the organization. No mechanized/atomized company has yet succeeded to produce with stopped equipment. Production buy availability performance from maintenance.

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Maintenance Cost Control

Maintenance CostAll enterprises and organizations are interested in lowering maintenance costs. A very common delusion is that

• The product gives the income• Maintenance costs money

Note: Maintenance which is not carried out ,will cost even more than money .

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Maintenance Cost Control

There are two ways of managing the maintenance costs

1. Cost Controlled Maintenance2. Result Controlled Maintenance

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Maintenance Cost Control

The cost controlled maintenance is not considered as modern maintenance management, The reason why maintenance has been treated as a cost controlled activity, Is often that engineers and technical staff have had some dilemma to measure the results of investments in maintenance in total economical terms. It is simple to find the direct cost for maintenance but it could be difficult to see the results. The upper priority in the objectives of maintenance is to “keep up planned availability performance at the lowest cost possible” . This means that the long term results are important. The maintenance cost must be put in relationship with overall results achieved by maintenance in production facility.

Contd…

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Maintenance Cost Control

Indirect & Direct Maintenance Costs

The maintenance cost can be split up in two different categories.

Direct maintenance costs -The costs are directly related to the performance of the maintenance works

Indirect maintenance costs -Losses due to maintenance

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Maintenance Cost Control

Direct maintenance costs• Wages & Salaries• Material Costs• Administration Costs• Costs for training• Spare parts costs• Contracted work forces• Modification Costs

Indirect Costs• Loss of revenue or other losses as a result of interruption to production as a result of maintenance.

Contd…

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Maintenance Cost Control

Measurement of Maintenance Efficiency

Many times there are needs to measure the maintenance efficiency. However, maintenance can not be measured by the cost it creates. There must be an connection to the production out put some way. It is naturally impossible to determine anything about the size of the direct costs. One method to control the direct maintenance is to use the PM-factor. “P” stands for prime product produce and “M” stands for maintenance cost. When using the PM-factor, the result of the maintenance impact on the production is measured. How many products are produced per a 1000 units of “maintenance money”.

PM – Factor = X Prime Production

Maintenance Cost

1000