Maintenance Management

Part 1
1). Objectives
2). Importance
3). Consequences
4). Cost
5). Maintenance Plan
6). Functions
7). Roles of Supervisor

Part 2

8). Type of Maintenance

9). Planned Maintenance
10). Maintenance Support
11). Health & Safety Aspects
12). Other Advantages

Maintenance Management
1). OBJECTIVES:

No unscheduled stoppages
Operating at high efficiency
High output capacity
High product quality
Low production cost
Low inventory cost

2). IMPORTANCE / DRIVING FORCES

Rising Material Cost
Rising Labour Cost
Competition
Environmental Protection
Safe working condition
Advent of Automation
Threat from other oils
High production level
Rising capital cost
Increase Machine Utilisation
Improving Technology

3). CONSEQUENCES

Poor team work

High product cost
High inventory cost
Poor product quality
Frequent breakdown
Low capacity
High product losses
High capital cost
High labour turnover

More Maintenance DOES NOT necessarily mean

BETTER MAINTENANCE
because it can take needed production
equipment to an extend that cost effective
maintenance has been submerged.
&
Good maintenance DOES NOT mean doing the
WRONG WORK EFFICIENTLY.

4. COST:
IS CONTROLLABLE because it is labour intensive.
- 4 Fundamental cost :
a). Direct
- require to keep equipment standby.
b). Standby
- operating & maintaining standby equipment
when primary facilities are down.
c) Production Lost - primary equipment is down and
NO standby.
d). Degradation
- equipment life deteriorated due to poor
maintenance.
-Which cost to control?
Controlling Direct Maintenance Cost will permit reasonable
control of the 4 fundamental costs.

WHAT ARE THESE DIRECT COSTS?

Wages & salaries.
Material cost
Administration cost
Training cost
Modification cost
Contract work

THE HIDDEN COST

MAINTENANCE

Quality Losses

Production Losses
Capital Cost

Energy Losses

Lost Market

Increased Investment

Capacity Losses

Work Environment

5). MAINTENANCE PLAN

4 Basic Plans

Central
Maintenance

Area
Maintenance

Work in any
Assigned to
or all areas
Specific areas &
& report to foreman report to foreman

Unit
Maintenance
Assigned to an
unit & report to
Supervisor, sometimes
to foreman &
to supervisor

Contract
Maintenance
Assigned to
qualified &
reliable
contractors

MAINTENANCE DEPARTEMENT
FUNCTIONS :
Maintenance

4 Categories
work undertaken in order to keep or
restore equipment to an acceptable
standard.

Installation & Alteration of plant equipment & services.

Operation & Supervision of particular utilities & special
services.
Miscellaneous

duties delegated to the Department.

MAINTENANCE DEPARTEMENT
THE PRIME REASON FOR ITS EXISTENCE IS TO
ENSURE THE AVAILABILITY AND EFFICIENCY
OF EXISTING PLANT, EQUIPMENT AND BUILDING
IN A MANNER REQUIRED BY THE PROCESSING
OR PRODUCTION DEPARTEMENT.

IN TERM OF MILL OPERATION

THIS MEANS THAT :
Mill MUST BE available for start-up when required.
Mill MUST NOT breakdown during Production runs.
Mill MUST Operate in an EFFICIENT manner at the
REQUIRED LEVEL of Production.
The downtime for maintenance MUST NOT interfere
with Production schedules.
The downtime which may be caused by a breakdown
should be MINIMUM.

HOW TO ACCOMPLISH THESE ?

Complete Co-operation & Mutual Understanding
between Maintenance & Production.
An effective Maintenance Policy for PLANNING,
CONTROLLING & DIRECTING all Maintenance
activities.
Well organized maintenance division, Adequately
Staffed & Trained to carryout the Work.
Progressive efforts to reduce or eliminate Breakdowns.

ROLES OF SUPERVISOR
Request for services.
Work Postponed,Delayed & Held over as a result.
emergency demand, change of operational requirements
& spares material not available.
Regular inspection of Running Plant.
Feedback on operating conditions.
Advice on Technical Matters.
Discussion on Variation of operations.
Fault Diagnosis.
Co-operation on fault-findings & Repairs.
Higher standard of Housekeeping
New Installation.

SETBACKS OF SUPERVISOR

Unable to Provide Technical Assistance.

Unqualified to direct Maintenance Job.

May neglect Job to meet schedules.
Responsibility may be divided.

WAYS TO OPERATE THE EQUIPMENT

4 Ways

REPLACEMENT
- Cheap
- Obsolete
- Beyond repair
- Easily replaceable
- Design not to last

PLANNED
REPLACEMENT
- Cheap
- Individual Unit
- New Technology
- Only basic
Maintenance

BREAKDOWN
MAINTENANCE
- Individual Unit
- Cheap
- Not affecting Production
- No safety hazard

PLANNED
MAINTENANCE
- Expensive
- Continuous Process
- High breakdown cost

TYPE OF MAINTENANCE
MAINTENANCE
PLANNED

UNPLLANNED

(Organised, & Carried out

forethought, Control &
records)

PREVENTIVE

PREDICTIVE

CORRECTIVE

IMPROVEMENT

(Performad regularly
to avoid failure to a
facility)

(Carried out before

time of failure)

(To restore a facility

to an acceptable
standard)

(to design out the

failure to avoid
recurring)

RUNNING

SHUTDOWN

BREAKDOWN

(Whilst the facility is

(Performed when a
facility is taken off
service)

(After a failure but

with advance
Provision)

in service)

EMERGENCY
(necessitated
unforeseen
breakdown or
damage)

PLANNED MAINTENANCE
PLANNED

PREVENTIVE

PREDICTIVE

- Fixed Time Maintenance

Conditioned Based

Maintenance
- Cleaning
- Lubrication
senses)
- Fixed Time Replacement

- Continuous (on line)

- Subjective (human
- Objective (off line)

IMPROVEMENT MAINTENANCE
OBJECTIVES :
Design out Failure
Extend part Life
Conducive working condition
Environmental Requirement
User Friendly
Better Housekeeping
Better Performance
Lower Cost
Better Quality

IMPROVEMENT MAINTENANCE
POINT TO CONSIDER FIRST :

Installation
Design Specifications
Quality of Parts Used
Technical Specifications

PLANNED MAINTENANCE
PHILOSOPHY
Ideally, all Maintenance should be PREVENTIVE.
Dynamic in nature, decisions made are constantly
charging.
Actually starts before the equipment is built or
purchased.
Not restricted to large-scale, multi-craft activities.

PLANNED MAINTENANCE
Questions to Ask Before Deciding on P.M.
Is this critical item? If it fail will it cause major
SHUTDOWN, or costly damage, or Harm to an
employee PM is almost certain.
Is standby equipment available in case of failure ?
Does cost of PM exceed expanse of downtime & cost
of repair or replacement ?
Does the normal life of the equipment without PM
exceed processing needs ? If obsolescence is expected
sooner than decay, PM may be a waste of money.

PLANNED MAINTENANCE
Basic of ANY P.M.SYSTEM is deciding in ADVANCE :
Individual items of plant & equipment to be maintained.
Form of Maintenance.
Method & Details of how is to be maintenance.
Tools required.
Material & spares required.
Who to carry out.
How long it will take.
Frequency required
Method of implementation.
Method of Analyzing the results.

PLANNED MAINTENANCE
NOT A PANACEA FOR EVERY MAINTENANCE PROBLEM.
IT WILL NOT COMPENSATE FOR :
Poor Work man ship
Lack of Tools
Bad Design
Mal Operation
Convert worn-out obsolete equipment into modern, Highly
Efficient units.

PLANNED MAINTENANCE
THE SYSTEM INSTALLED SHOULD BE EASY TO
OPERATE, INVOLVE MINIMUM PAPER WORK BUT
MUST BE CAPABLE OF INDICATING CLEARLY :
1). WHAT IS TO BE MAINTAINED ?
2). HOW IT IS TO BE MAINTAINED ?
3). WHEN IT IS TO BE MAINTAINED ?
4). IS THE MAINTENANCE EFFECTIVE ?

COMPONENT OF A PLANNED
MAINTENANCE SYSTEM
ASSET REGISTER - Inventory of Plant & equipment.
MAINTENANCE SCHEDULE Schedules for inspection, lubrication,
Preventive maintenance & Planned overhaul.
WORK SPECIFICATIONAL Instruction cards or documents which
identifies exactly the tasks to be under taken.
CONTROL SYSTEM Trigger System which initiates the activities on the
programme at predetermined interval.
RESOURCING SCHEDULE - man power allocation for optimum usage of
labour.
RECORDS records of maintenance carried out and a system for reporting to
Management.
MAINTENANCE SUPPORT technical information, spare parts & tools.

 PLANNED OVERHAUL Provision for ensuring the planned overhaul of

equipment according to schedule or in response to condition monitoring.
COSTING Procedure to ensure adequate cost control.
TRAINING Necessary training of operatives & supervision in the operation
of the system.

PLANNED MAINTENANCE
CONTROL SYSTEM MUST CLEARLY IDENTIFY :
WHAT WORK IS TO be DONE.
WHAT MATERIALS are NEEDED.
WHEN THE WORK SHOULD be DONE.
HOW LONG it SHOULD TAKE.
WHAT SKILLS are NEEDED to perform the work.
WHAT SPECIAL TOOLS are NEEDED.

AID TO GOOD PLANNED MAINTENANCE

MATERIAL RESEARCH use of better material.
DESIGN CHANGES ensure failure due to design
weakness and not others.
MAINTENANCE TRAINING
OPERATOR TRAINING
STANDARD WORKING PRACTICE MANUALS
everyone knows the expectations.
STANDARDISATION.
SPECIAL REPORTS alert to problems.
MAINTENANCE STORE spare parts availability.
RECORDS ANALYSIS analyse failure

POLISHING THE PLANNED MAINTENANCE

PROGRAM
AVOID OVER MAINTENANCE.
GET ACCURATE COSTS.
CHECK INSPECTION FREQUENCIES.
PROVIDE SPECIFIC SKILL INSTRUCTIONS.
ADOPT REPAIR CODES.
USE MODERN DIAGNOSTIC TOOLS.
APPLY INDUSTRIAL ENGINEERING
TECHNIQUES.
UTILISE STATISTICAL AIDS.
DESIGN FOR LOW-COST MAINTENANCE.

MAINTENANCE SUPPORT
TECHNICAL STORE spare parts.

LUBRICATION HANDLING.
SUPPLIER (VENDOR) ASSISTANCE.
TECHNICAL MANUALS.
DRAWINGS.
ENGINEERING.
CONTRACT SPECIALISED TASK
FAULT ANALYSIS CHART

MAINTENANCE MANAGEMENT
SAFETY, HEALTH & ENVIRONMENT (S H E)
MAINTENANCE PLANNING CONTRIBUTIES TO SAFETY
BECAUSE :
- a well maintained safe plant remains in a SAFE STATE.
- if priorities are maintained the most important work is done FIRST
and NOT NEGLECTED.
- Statutory requirement will be MET.
- Safety guards, valves, interlock, etc will be REGULARLY
CHECKED.
- The possibility of pollution is REDUCED, where these risks exist.

The End