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Maintenance Management
All activities involved in keeping a systems equipment working Objective: Maintain system capability & minimize total costs
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
Employee Involvement
Information sharing Skill training Reward system Power sharing
Cost component
Employment of maintenance Administrative expenses Investment in maintenance equipment Stocking of repair parts
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
Limitations
The information or failure data is to be collected over a large population . It create difficult when equipment is unique.
Failure
Sudden failure
Gradual failure
strategy
Anticipate failure and prepared to take remedial measure
strategy
Preventive maintenance based on condition monitoring
Preventive measures Preventive measures attempts to prevent any probable breakdowns resulting in production stoppages. It follow a slogan_ Prevention is better than cure.
Evaluating Maintenance
Reliability
Probability that an item will function for a given time
Failure rate
Reciprocal of MTBF
FR(%) =
Number of failures
FR(n) =
Number of Failures
Operating Time
MTBF
1 FR(N)
Maintenance cost index = Maintenance cost * 100 capital cost Breakdown maintenance = Breakdown hours index Man hours available