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Maintenece mgmt. 2

  2. CONTENTS: 1. Introduction. 2. Objectives. 3. Maintenance cost. 4. Failure analysis. 5. Benefits of failure statistics. 6. Limitations. 7. Types of Maintenance.
  3. INTRODUCTION: • It is necessary to keep materials, tools and equipment in good condition in order to achieve desired result. • If the working equipments are in good running condition, the products obtained will be of required quality and the process will be reliable. • Therefore it is necessary to maintain the plant.
  4. MAINTENANCE: Maintenance is a set of organized activities that are carried out in order to keep the item in its best operational condition with minimum cost required.
  5. OBJECTIVES: • To increase functional reliability of production facilities. • To enable desired quality through correctly adjusted, serviced and operated equipments. • To maximize the useful life of equipments. • To minimize cost of production. • To minimize frequency of interruptions. • To enhance the safety of manpower.
  6. FUNCTIONS: 1. Inspection. 2. Repair. 3. Overhaul. 4. Lubrication. 5. Salvage.
  7. MAINTENANCE COST: 1. Because of breakdowns, both the machinery as well as the manpower are left idle, per force. 2. This results in production, delay in schedules and emergency repairs. 3. The downtime costs generally exceed the preventive maintenance costs of inspection, service and scheduled repairs.
  8. COSTS ASSOCIATED WITH MAINTENANCE ARE; 1. Downtime cost due to equipment breakdown. 2. Cost of spares and other material used for repairs. 3. Cost of maintenance labour and overheads of maintenance department. 4. Losses due to inefficient operations of machines. 5. Capital requirement for replacement of machines.
  10. Failure Analysis strategy strategy
  11. BENEFIT OF FAILURE STATISTICS: 1. Helps to diagnose failures when they occur. 2. Provides valuable information regarding the life and reliability of the equipment. 3. Helps to take maintenance policy decisions. 4. Information for Spare Parts Department.
  12. LIMITATIONS: 1. When the failure is due to inherent quality of the equipment. 2. Manufacturing defects. 3. Poorly installed equipments . 4. Damage due to improper handling of equipments .
  13. TYPES OF MAINTAINANCE: • The various types of maintenance and their relationship can be seen below:
  14. PREVENTIVE MAINTENANCE SYSTEMS : 1. Proper identification of all the items, their documentation and coding. 2. Inspection of plant and equipment at regular intervals. 3. Proper cleaning and lubrication of equipments. 4. It helps to upkeep the machines through minor repairs. 5. Failures are analyzed in order to eliminate future failures.
  15. CORRECTIVE MAINTENANCE: 1.Organized maintenance work intended to restore a failed unit. 2. It includes different types of actions like typical adjustments to redesign equipments. 3. It is a one time job and each corrective maintenance activity undertaken should be completed fully. 4. The emphasis in corrective maintenance is on obtaining full information of all breakdown and their causes.
  16. PREDICTIVE MAINTENANCE: Predictive Maintenance as the name implies predicting the failure before it occurs, identifying the root causes for those failures symptoms and eliminating those causes before they result in extensive damage to the equipment.
  17. RUNNING MAINTENANCE: It includes the maintenance activity that are carried out while the machine or equipment is running and they represent those activities that are performed before the actual preventive maintenance activities takes place.
  18. SCHEDULED MAINTENANCE It is a scheduled service visit carried out by an agent, to ensure that an item of equipment is operating correctly and to therefore avoid any unscheduled breakdown and downtime.
  19. SHUTDOWN MAINTENANCE: Maintenance that can only be performed while the equipment is shutdown.
  20. BREAKDOWN MAINTENANCE: Repairs or replacements performed after a machine has failed to return to its functional state following a malfunction or shutdown.