Академический Документы
Профессиональный Документы
Культура Документы
Girish Kant
Department of Mechanical Engineering
ENGG ZC242, Maintenance and Safety,
05/08/2014, Lecture-2
BITS Pilani
Pilani Campus
Introduction to Maintenance
Systems
Chapter 1, Lecture -2
Learning Objectives
Maintenance Objectives/Scope and Benefits/Policies
3
BITS Pilani, Pilani Campus
Maintenance Objectives
Operational
Cost
Minimize maintenance expenditure and maximize profits
To provide activities with in the limits of budgetary control
4
BITS Pilani, Pilani Campus
Maintenance Benefits
Financial
Organizational
Technical
Human
Customer relations
5
BITS Pilani, Pilani Campus
Financial Benefits
Extended Plant Life
Uninterrupted production
Improved quality of production
Reduced production delays
Reduced cost of repairs
6
BITS Pilani, Pilani Campus
Organizational Benefits
Co-ordination between production and maintenance
7
BITS Pilani, Pilani Campus
Technical Benefits
Improved equipment suitability
8
BITS Pilani, Pilani Campus
Human considerations
Benefits
Increased Safety
9
BITS Pilani, Pilani Campus
Customer relationship
Benefits
Reliable delivery calls
10
BITS Pilani, Pilani Campus
Maintenance Policy
Scope and limits of maintenance
11
BITS Pilani, Pilani Campus
Maintenance Functions
Primary Functions
Secondary Functions
Storekeeping
Plant protection
Waste disposal
Salvage
Insurance
Other services
12
BITS Pilani, Pilani Campus
13
BITS Pilani, Pilani Campus
Maintenance as Business
Proposition
The maintenance costs continue to capture the attention
of senior management as the investment and reliability in
assets become increasingly greater.
The business unit concept
Automation
Maintenance cost reduction
14
BITS Pilani, Pilani Campus
Maintenance as Business
Proposition
15
BITS Pilani, Pilani Campus
Maintenance Philosophy
Most people think of the maintenance function as:
16
BITS Pilani, Pilani Campus
Types of Maintenance
Systems
Breakdown
Reactive
Preventive
Predictive
17
BITS Pilani, Pilani Campus
Planned Maintenance
Essential Care(EC): This includes preventing failures
from occurring with tasks such as detailed cleaning,
lubrication, alignment, balancing, operating procedures,
adjustments, and installation procedures.
Fixed-Time Maintenance(FTM): It constitutes all
replacements that are done on a fixed schedule
regardless of condition, e.g. programmed replacements
and overhauls
Condition monitoring(CM): It constitutes all inspections
from simple subjective tasks such as look, listen, feel,
smell etc. to objective tasks such as vibration analysis,
oil-sampling, ultrasonic leak detection, pressure checks,
current readings etc.
ENGG ZC242, Maintenance and Safety,
05/08/2014, Lecture-2
18
BITS Pilani, Pilani Campus
19
BITS Pilani, Pilani Campus
Preventive Maintenance
Programmme Risks
Damage to an adjacent equipment during a PM task.
Damage to the equipment receiving the PM task.
Damage during the performance of an inspection,
repair, adjustment or installation of a replacement part.
Installing material that is defective, incorrectly installing
a replacement part or incorrectly reassembling material.
Reintroducing infant mortality by installing new parts or
materials.
Damage due to an error in reinstalling equipment into its
original location.
ENGG ZC242, Maintenance and Safety,
05/08/2014, Lecture-2
20
BITS Pilani, Pilani Campus
Preventive Maintenance
Program
Identify the critical equipments
List the subsystems and parts for the identified
equipments
Determine the preventive maintenance procedure for
each of the subsystem and parts
Prepare a details work instruction for each procedure
Fix the frequency for each activity
Prepare a PM Calendar for the plant
21
BITS Pilani, Pilani Campus
Preventive Maintenance
22
BITS Pilani, Pilani Campus
Bush bearing
Roller / Ball bearing
Gear assembly
Belt & Pulley
Chain & Sprocket
Key
Spline
Clutch
Lead-screw & Nut
Coolant system
Lubrication system
ENGG ZC242, Maintenance and Safety,
05/08/2014, Lecture-2
23
BITS Pilani, Pilani Campus
24
BITS Pilani, Pilani Campus
Proactive Maintenance
If a disease is pinpointed and eliminated long before any
symptoms occur in your body, it would save your money
in doctor bills and keep you out of hospital in the long
run.
Proactive maintenance commissions corrective action
aimed at the source of failure.
25
BITS Pilani, Pilani Campus
Predictive Maintenance
The condition of the equipment or machinery is predicted
by observing the signals it emits based on which the
maintenance action is taken
This maintenance is also called condition monitoring
The monitoring can be done online or offline
26
BITS Pilani, Pilani Campus
Predictive Maintenance
27
BITS Pilani, Pilani Campus
Summary
Comment on the following statements
Maintenance is a necessary evil
Maintenance is a bottomless pit for expenses
Maintenance is known as Time lag effect
28
BITS Pilani, Pilani Campus
Thanks
29
BITS Pilani, Pilani Campus