Explain the importance of maintenance in FM Field.
Describe the range of maintenance activities.
Discuss preventive maintenance and the key issues associated with it.
Discuss breakdown maintenance and the key issues associated with it.
2. Objectives
• Explain the importance of
maintenance in FM Field.
• Describe the range of maintenance
activities.
• Discuss preventive maintenance and
the key issues associated with it.
• Discuss breakdown maintenance and
the key issues associated with it.
3. WHAT IS MEANT BY THE
TERM “MAINTENANCE” ?
• Maintenance encompasses all those activities that
maintain facilities & equipment in good working order so
that a system can perform as intended.
• Maintenance can also be termed as asset management
system which keeps them in optimum operating
condition
4. • Modern maintenance management is not to repair broken equipment
rapidly. Modern maintenance management is to keep the equipment
running at high capacity and produce quality products at lowest cost
possible.
• Many years ago, the manufacturing and production work was done
with relatively simple technical equipment and the involvement of
more manpower.
• Maintenance was of course simple and impact to certain extent to the
function of machines.
• During the industrialization, production equipment has been more
developed. In connection with the high technical development the
impact of productivity and quality has moved from man to machine.
5. • The importance of maintenance has considerably increase
• There are many reasons why maintenance is becoming more and
more important. In developing countries , where many old machines
are operating, the spare part problem are arising. Sometimes it is
difficult to find spare parts for equipment and if it is possible to find
them, they are usually very expensive
• Due to long lead times of supply of spares, it is common that the
spare part inventory is growing bigger than necessary. A very essential
part in maintenance management is developing countries to reduce
the need of spare parts, as well as to maintain the minimum level of
shock to save foreign currency but keeping the productivity high.
6. Life Cycle Cost
The bathtub curve describes the cost of equipment over its lifespan. From commissioning to winding up.
7. Maintenance Cost
• All enterprises and organizations are
interested in lowering maintenance
costs. A very common delusion is that
9. The cost-controlled maintenance is not considered as modern maintenance management, The
reason why maintenance has been treated as a cost-controlled activity, Is often that engineers
and technical staff have had some dilemma to measure the results of investments in
maintenance in total economical terms. It is simple to find the direct cost for maintenance, but
it could be difficult to see the results.
The upper priority in the objectives of maintenance is to “keep up planned availability
performance at the lowest cost possible” . This means that the long-term results are important.
The maintenance cost must be put in relationship with overall results achieved by maintenance
in production facility.
10.
11. GOAL OF MAINTENANCE
• Goal of maintenance is to keep the
equipment's in good working order at
minimal cost.
• Decision makers have 2 basic options with
respect to maintenance. They are: -
–BREAKDOWN MAINTENANCE.
–PREVENTIVE MAINTENANCE.
12. TYPES OF MAINTENANCE
BREAKDOWN MAINTAINANCE:-
–Real approach,
–Dealing with breakdowns or problems when they
occur…
PREVENTIVE MAINTENANCE:-
–Proactive approach;
–Reducing breakdowns through a program of
lubrication, adjustment, cleaning, inspection, and
replacement of worn parts.
13.
14. PREVENTIVE MAINTENANCE
• More and more organizations are taking a cue from the Japanese
and transferring routine maintenance (e.g., cleaning, adjusting,
inspecting) to the users of equipment, in an effort to give them a
sense of responsibility and awareness of the equipment they use
& cut down the abuse & misuse of the equipment.
• Preventive maintenance extends back to the design and selection
stage of equipment and facilities.
• Poor design can cause equipment to wear out at an early age or
experience a much higher than expected breakdown rate.
• Durability and ease of maintenance can have long term
implications for preventive maintenance programs.
• Training employees in proper operating procedures and in how to
keep equipment in good operating order – and providing the
incentive to do so – are also important.
15. The goal of preventive
maintenance
• Preventive maintenance is periodic.
• Preventive maintenance is generally scheduled
using some of the following contributions:-
• The result of planned inspections that reveal a need for
maintenance.
• According to the calendar (passage of Time).
• After a predetermined no. of operating hours.
16. What is a Preventive
Maintenance?
• –Preventive Maintenance is
planned maintenance that is
designed to improve
Equipment life and avoid
breakdowns on the plant.
18. PREDICTIVE
MAINTENANCE
•This is an attempt to
determine when best to
perform preventive
maintenance.
•The better the predictions of
failures are, the more effective
preventive maintenance will be.
19. Predictive
Maintenance
•Predictive maintenance is often the most
attractive concept, since action is only
undertaken when knowledge of the asset
indicates that failure or underperformance is
imminent, making it a cost-effective asset
management option.
Predictive maintenance is a process that
requires clear roles and responsibilities. As
such we develop company appropriate
predictive maintenance processes,
supported by definitions of responsibilities,
and communication paths, which integrate
into the Reliability effort as a whole.
20. Condition monitoring facilitates
Predictive Maintenance.
• Condition monitoring is a
knowledge-based activity, so for it to
be successful and sustainable, it
requires comprehensive skills
training. Any successful predictive
maintenance program, not only has
a technology element, but requires a
measurement system that
continuously accounts for the
benefits.
21. Total Preventive Maintenance
JIT approach where workers perform preventive maintenance on the
machines they operate.
This approach is consistent with JIT systems and lean production, where
employees are give greater responsibility for quality, productivity and the
general functioning of the system.
22. BREAKDOWN
MAINTENANCE
• The risk of a breakdown can be greatly reduced by an
effective preventive maintenance program.
• The major approaches used to deal with breakdowns
are:-
• Standby or backup equipment can be quickly pressed
into service.
• Inventories of spare parts.
• Operators who are able to perform at least minor
repairs on their equipment.
• Repair people who are well trained and readily
available to diagnose and correct problems with
equipment.
24. Improvement
Maintenance
• Improvement maintenance is used When to
modify the equipment, so the Condition
improves. Improvement Maintenance
includes activities which are carried out
once. The objectives of improvement
maintenance are to Design out the failure
i.e. the failure Will never occur again or
extend the lifetime of parts.
