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MAINTENANCE MANAGEMENT

Maintenance Management
All activities involved in keeping a systems equipment working Objective: Maintain system capability & minimize total costs

1995 Corel Corp.

The maintenance policy is framed to answer the questions like:What we plan to do about breakdowns of machines ? What steps are we going to take to prevent the breakdowns ?

Maintenance Performance
Employee Involvement Maintenance Procedures

Maintenance Performance

1995 Corel Corp.

1995 Corel Corp.

Employee Involvement
Information sharing Skill training Reward system Power sharing

1995 Corel Corp.

Maintenance & Reliability Procedures


Clean and lubricate Monitor and adjust Minor repair Computerized records
Maintenance Procedures

1995 Corel Corp.

Cost component
Employment of maintenance Administrative expenses Investment in maintenance equipment Stocking of repair parts

Result of Absence of maintenance


Machine breakdown Production stoppage Idle machine-time Idle direct and indirect labor time

Poor quality of production Increased scrap Failure to meet delivery promises Industrial accidents Decline the morale of worker

Maintenance Benefits
Reduced inventory Lower operating costs Faster

Improved capacity

Maintenance

Higher productivity

Continuous improvement

Improved quality

Maintenance objectives
To increase functional reliability of production facilities. To achieve the specified quality of product. To maximize the useful life of the equipment. To minimizing the frequencies of interruption to production by reducing breakdowns. To enhance the safety of manpower.

Failure analysis
Y-Values
3 2.5

RATE OF FAILURE

2
1.5 1 0.5 0 0 0.5 1 1.5 2 2.5 Y-Values

Time

Benefits of failure statistics


Helps to diagnose failures when they occur. Provide a valuable information regarding the life and reliability of the equipment to the design engineer. Failure statistics helps to take maintenance policy decisions as to whether to opt for repair or preventive or replacements options. It is important information for spare parts management.

Limitations
The information or failure data is to be collected over a large population . It create difficult when equipment is unique.

Failure occur due to


Manufacturing defects Poorly installed equipment or machinery Improper handling , accidents etc.

Failure

Sudden failure

Gradual failure

strategy
Anticipate failure and prepared to take remedial measure

strategy
Preventive maintenance based on condition monitoring

Types of maintenance system


Repair maintenance when any sudden breakdown occurs in any machine or plant service , the repair maintenance staff endeavors to locate any mechanical , electrical or some such fault and to correct it immediately.

Preventive measures Preventive measures attempts to prevent any probable breakdowns resulting in production stoppages. It follow a slogan_ Prevention is better than cure.

Preventive measure carried as :


Elimination of overloading on equipment or plant services. Regular cleaning , greasing and oiling of the moving parts. Replacement of worn out parts before they fail to operate. Periodic overhauling of the entire machine.

Preventive maintenance function is subdivided as under:


Preventive maintenance of production departments. 1 Anticipatory inspection and servicing of equipment. 2 Routine maintenance Preventive maintenance of plant services.

Evaluating Maintenance
Reliability
Probability that an item will function for a given time

Mean time between failures (MTBF)


Average time between failures of a repairable item

Failure rate
Reciprocal of MTBF

Failure Rate (%)

FR(%) =

* 100% Number of units tested

Number of failures

Failures Per Operating Hour

FR(n) =

Number of Failures

Operating Time

Mean Time Between Failures

MTBF

1 FR(N)

Maintenance performance ratios


Waste index = Waste Quantity(WQ) Output Quantity(OQ) Productivity of maintenance = Output(product) Maintenance cost

Maintenance cost index = Maintenance cost * 100 capital cost Breakdown maintenance = Breakdown hours index Man hours available

Down time index = Down time hours * 100 production hours

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