1. 4/11/2013
Maintenance Management – Why?
• Breakdown of one piece of equipment or component can
hinder the performance of the entire production process,
resulting in delays.
• Repairing a machine can be much more expensive once it
Maintenance Management breaks down.
• Malfunctioning equipment may affect the quality of
product.
Presented By: • Scrap due to such equipment increases the unit production
Anupam Kumar cost.
Reader • During machine breakdown, the workers become idle
resulting in higher unit cost of the product.
SMS Varanasi
• Machine failure can even lead to accident in some cases.
Objectives of Maintenance
Maintenance Management
Management
• Maintenance Management is planning, • Maximize the availability of firm’s assets for production
purposes.
organizing and controlling of maintenance • Preserve the value of the firm’s machinery and equipment
activities such that the overall maintenance by reducing the rate of deterioration.
• To anticipate and prevent machine failure and breakdowns.
cost is minimized. • Improve the quality of products and increase the firm’s
• It strives to maintain optimum equipment productivity.
• Use maintenance personnel and equipment efficiently.
conditions in order to prevent unexpected • Minimize repair cost and repair time.
breakdowns, speed losses and quality defects • Minimize or totally eliminate accidents by regular
arising from process activities. inspection and repairs.
• Efficient use of maintenance personnels.
Scope of Maintenance Management Primary Maintenance Functions
• All segments of the plant including the building, • Maintenance of exiting plant, equipment,
machinery, equipment, plant, tools, cranes, jigs & buildings, land, etc.
fixtures, heating and air-conditioning • Equipment inspection and lubrication
equipments, generators, waste disposal systems,
washrooms, dispensaries, etc need maintenance. • Utilities generation and distribution
• Maintenance management can broadly be • Alterations to existing equipment and building
categorized into 2 functions: • New installation of equipment & buildings
– Primary Function
– Secondary Functions
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2. 4/11/2013
Secondary Maintenance Functions Benefits of Maintenance Management
• Store keeping (keeping stock of spare parts, etc.) • The production capacity of the facility remains
unaffected due to well maintained machines and thus
• Plant protection including fire protection lesser breakdowns.
• Waste disposal • Production cost can be kept minimum.
• Salvage • Quality of products and services can be maintained
• Insurance administration (against fire, theft, etc.) due to reduced variation in output
• Janitorial Services • Increased safety of the workers due to reduction in
accidents.
• Property Accouting • Delivery schedule of the customers can be maintained.
• Pollution and noise control • Life of facilities and equipment increases.
• Any other service delegated to maintenance by plant
management.
Objectives of Breakdown
Types of Maintenance
Maintenance
• There are basically two types of maintenance: • To get the equipment back into operation as
– Breakdown Maintenance quickly as possible.
• It is a reactive approach in which repairs and replacement of
parts are performed only when the breakdown occurs. • To control the cost of repair crews
– Preventive Maintenance
• To control the cost of operation of repair
• It is a periodic activity in which the time of maintenance can
be scheduled shops.
• either according to a calendar dependant upon the
predetermined number of operating hours of different • To control the investment in replacement
equipment spare parts
• or on the basis of inspection of the equipment to find its
state and need for maintenance. • To perform appropriate amount of repair at
each malfunction.
Advantages of Preventive
Preventive Maintenance
Maintenance
• Preventive Maintenance involves • Increase in life of machines & equipments by
– Proper design and installation of equipment reduction of wear & tear
– Periodic inspection of plant and machinery to • Reduction in frequency of breakdowns.
prevent break-downs before they occur. • Improvement in productivity due to lesser machine
– Repetitive servicing, upkeep and overhaul of down-time and consequent loss of production.
equipment. • High reliability of production systems due to lesser
– Adequate lubrication, cleaning and painting of breakdown and repairs
building and equipments • Higher worker safety while using the plant and
equipment.
• Its aim is to minimize the possibility of
unanticipated break-downs.
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3. 4/11/2013
Advantages of Preventive Limitation of Preventive
Maintenance Maintenance
• Planned shutdowns and start-ups of plant and • More expensive in short term and during the
equipment possible. initial stages of introduction of preventive
• Lesser requirement of stand-by machines due to maintenance program.
lesser break-downs.
• Inspection of plant, equipment and machinery
• Minimum work-in-progress inventory due to reduced
will have to be carefully planned and
production hold ups due to equipment breakdowns.
implemented and improved over a period of
• Lesser rejection and better quality control
time.
• Less serious consequences of break-down and lesser
break-down maintenance costs.
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