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C o n f i d e n t i a l1
Program : MBA
Semester : IV
Subject Code : OM0015
Subject Name : Maintenance Management
Unit number : 1
Unit Title : Introduction, Needs and Importance of
Maintenance
Lecture Number : 1
Lecture Title : Introduction, Needs and Importance of
Maintenance
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Objectives
The objectives of this lecture are to:
• Discuss Maintenance Management
• Explain the Need and Importance of Maintenance
• Discuss the Types of Maintenance
• Describe the Organisational Objectives and Functions of Maintenance
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Unit-1 Introduction, Need and Importance of Maintenance Management
Introduction, Need and Importance of Maintenance Management
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Lecture Outline
• Introduction
• Maintenance Management
• Objectives
• Classifications
• Need and Importance
• Organisational Objectives
• Functions and Policies
• Capability Factors
• Widely Adopted Methods
• Summary
• Check Your Learning
• Activity
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Unit-1 Introduction, Need and Importance of Maintenance Management
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Introduction
• Maintenance is the fundamental requirement for keeping up
productive resources in good working condition throughout their
lifetime.
• Maintenance management is the systematic approach involved in
planning the maintenance activities to improve the overall efficiency
of the entire operating system.
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Unit-1 Introduction, Need and Importance of Maintenance Management
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Maintenance
The steps involved in maintenance are:
• To understand the current maintenance process
• To determine if the current process suits the task
• To list out process improvement actions
• To plan action in order to perform the required tasks
• To commit resources to execute the task as per the time frame
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Unit-1 Introduction, Need and Importance of Maintenance Management
C o n f i d e n t i a l
Objectives
The main objectives of maintenance management involve:
• Planning maintenance activities and evolving policies• Creating an organisational structure for the department• Organising maintenance resources• Directing execution of maintenance plan• Controlling the performance of maintenance activities• Defining processes for performing maintenance• Budgeting and controlling costs
Unit-1 Introduction, Need and Importance of Maintenance Management
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Classification
Maintenance process can be classified into five groups:
Unit-1 Introduction, Need and Importance of Maintenance Management
Group 1: Maintenance is carried out while the equipment is running.
Group 2: Maintenance is carried out on an idle machinery.
Group 3: Machine or equipment is taken out of the production for scheduled
maintenance.
Group 4: Equipment or machine has failed and is readily available for
maintenance.
Group 5: The equipment has failed but it is waiting for maintenance.
Maintenance
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Need and Importance
The factors that have created the need for maintenance management
include:
• Higher operating costs
• Environmental concerns
• Safety issues
• Warranty and liability factors
• Regulatory matters
• Ageing of plant
• Increased cost of replacement
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Unit-1 Introduction, Need and Importance of Maintenance Management
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Importance
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Unit-1 Introduction, Need and Importance of Maintenance Management
The implementation of maintenance management is inevitable
because of the following:
• Break down of machinery hinder the performance of the
production process
• Repair of machinery is expensive once it breaks down
• Quality of the product suffers if machines malfunction
• Workers become idle during breakdown and repair time
• Machine failure may lead to accidents in some cases
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Organisational Objectives
The organisational objectives achieved by a good maintenance
management are as follows:
• Reduction in the loss of productive time• Minimum repair time and cost• Optimum use of resources and facilities• Extend the life of costly capital assets• Provide effective and efficient use of maintenance personnel• Improve the quality of productive assets
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Unit-1 Introduction, Need and Importance of Maintenance Management
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Unit-1 Introduction, Need and Importance of Maintenance Management
Functions
The functions of the maintenance management include:
• Maintenance of buildings and services
• Inspection and lubrication of machinery and equipments
• Maintenance of utilities and distribution
• Installations of new equipments
• Alterations to the assets for ease of work
• Maintenance of existing plant and machinery
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Highlights of a good maintenance policy involve:
• Encouraging the right maintenance practices
• Providing the backup for machines evolved in critical operations
• Replacing parts before they are expected to fail
• Ensuring proper training of the machine operators
• Designing machines for maintainability and quick repair
provisions
• Enhancing staff capability factor and thus building flexibility for
cross functional activities
• Stocking adequate spare parts to reduce downtime
• Improving process for reduced wear and stress on machines
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Unit-1 Introduction, Need and Importance of Maintenance Management
Maintenance Policies
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Factors enhancing the capability and effectiveness of maintenance
include:
• Work management policy
• Well structured training strategy
• Optimal resource management
• Quality assurance in all activities
• Outsourcing plan and procedures
• Commitment of the maintenance personnel
• Supervisory role
• Process improvement and measurement
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Unit-1 Introduction, Need and Importance of Maintenance Management
Capability Factors
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Widely adopted maintenance techniques are:
• Routine maintenance• Planned maintenance • Break down maintenance• Corrective maintenance• Remedial maintenance • Preventive maintenance• Predictive maintenance• Condition based maintenance• Total productivity maintenance
Widely Adopted Techniques
Unit-1 Introduction, Need and Importance of Maintenance Management
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Summary
• Maintenance management is concerned with the direction and
pooling of all internal resources to control the availability and
performance of the equipments and machineries at expected levels.
• It is very essential for any organisation to emphasise and establish an
efficient and effective maintenance department.
• Maintenance management has to define and establish sound
maintenance practices and processes.
• Maintenance is categorised as preventive, predictive, and remedial.
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Unit-1 Introduction, Need and Importance of Maintenance Management
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Check Your Learning
1. Name five maintenance techniques
Ans. The five maintenance techniques are:
Routine Maintenance, Planned Maintenance, Preventive Maintenance,
Predictive Maintenance and Condition Based Maintenance
2. State whether true or false:
i) Routine Maintenance is a cyclic operation recurring periodically
Ans. True – Routine Maintenance is a procedure followed regularly
ii) Repairing machinery is inexpensive once it breaks down
Ans. False – It gets very expensive to get the machine repaired once it
reaches the breakdown stage. It also affects the production and labour
hours.
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Unit-1 Introduction, Need and Importance of Maintenance Management
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Activity
List out the main areas where condition based maintenance
can be implemented.
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Unit-1 Introduction, Need and Importance of Maintenance Management