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Edit Comment Close Premium member Presentation Transcript Slide 1: Maintenance Genesis Presented by : Group 2 (Batch 18B) Group 2- Members : Group 2- Members Richa KH2009SMBA18P038 Venkatesh KH2009SMBA18P054 Diptesh KH2009SMBA18P066 Jasmeet KH2009SMBA18P070 Ramya KH2009SMBA18P101 Ankur KH2009SMBA18P104 : Genesis A beginning or origin of anything Maintenance It is the work of keeping something in proper condition Maintenance Genesis Breakdown Consequences : Breakdown Consequences Production capacity is reduced Orders are delayed No production Overhead continues Cost per unit increases Quality issues Product may be damaged Safety issues Injury to employees Injury to customers Goal of Maintenance : Goal of Maintenance To keep production systems in good working condition at minimal cost To ensure maximum ‘availability’ of the operation Reasons for maintenance To avoid production or service disruptions To not add production or service costs To maintain high quality To avoid missed delivery dates Availability : Availability Reliability Probability that the item will not fail Maintainability The probability that the item is successfully restored after failure Availability Probability that a system is not failed or undergoing a repair action when it needs to be used Maintenance Management Prior to World War II : Maintenance Management Prior to World War II Reactive Maintenance Breakdown maintenance Reactive approach Dealing with breakdowns or problems when they occur Challenges : Poor planning Incomplete repair Slide 8: Maintenance Management Post World War II Year - 1950 : Preventive Maintenance To prevent the failure of equipment before it actually occurs through: Periodic maintenance ( Time based maintenance - TBM) Predictive maintenance Year - 1950 Periodic maintenance : Time based maintenance (TBM) Servicing and cleaning equipment Inspection Oiling Replacing parts Periodic maintenance Predictive maintenance : Service life of important part is predicted based on : Inspection Diagnosis Parts are used to the limit of their service life. It involves condition based maintenance. Measures and analyze data about deterioration. Monitor conditions through on-line system. Predictive maintenance Condition Based Maintenance (CBM) : To assess machinery condition it uses: Non destructive testing techniques Visual inspection Performance data Ultimate Goal of CBM: Eliminate routine maintenance Service equipment only when monitoring system indicates Key components of CBM: Vibration monitoring Thermography Oil analysis Condition Based Maintenance (CBM) Vibration monitoring : Monitors frequencies to predict impending defect Compares the vibration spectra of new equipment vs. subject equipment Vibration monitoring Thermography : Analysis of thermal information by using non contact thermal imaging devices. Thermography Worn refractory insulation causing hotspot Oil Analysis : Detecting the presence of contamination in oil. Example: Electrical transformer’s oil analyzed for the presence of carbon deposits Analyzing High Engine Oil consumption Oil Analysis Benefits of preventive maintenance : Improved system reliability. Decreased cost of replacement. Decreased system downtime. Better spares inventory management. Benefits of preventive maintenance 1957 - Corrective Maintenance : Equipment with design weakness must be redesigned to improve: Reliability Maintainability Preventive Maintenance Analyzing techniques: Root cause analysis FMEA 1957 - Corrective Maintenance Root Cause Analysis : Root Cause Fundamental breakdown or failure When resolved, prevents recurrence of the problem. Techniques: “Why-Why” Analysis Causal Tree Fish Bone Diagram Root Cause Analysis Year - 1960 : Poka-yoke - Eliminates defects By preventing or correcting mistakes as early as possible. Applied in processes potential of inducing catastrophic in-service failures. Year - 1960 “I have an extra part. I must have omitted a step!” 1960 - Maintenance prevention : It indicates the design of a new equipment. Weakness of current machines are sufficiently studied and incorporated before commissioning a new equipment. Prevents Maintenance Improves “Availability” Example: Using powder metallurgy built porous bronze bearing for ceiling fans Improved automobile batteries 1960 - Maintenance prevention 1963 - Productive Maintenance : Preventive maintenance + Maintenance prevention = Productive maintenance + Maintainability Improvement Maximize plant and equipment effectiveness Achieve optimum life cycle cost of production equipment. 1963 - Productive Maintenance 1971 - Total Productive Maintenance : 1971 - Total Productive Maintenance Uniqueness of TPM : The concept of "I (Production operators) Operate, You ( Maintenance department ) fix" is not followed. Uniqueness of TPM TPM Objectives : Zero Defects Zero Breakdown Zero accidents Involve people in all levels of organization. TPM Objectives Direct benefits of TPM : Obtain Minimum 80% Overall Plant Efficiency Obtain Minimum 90% Overall Equipment Efficiency Rectify customer complaints. Reduce the manufacturing cost by 30%. Satisfy the customer’s needs by 100 % Reduce accidents. Follow pollution control measures. Direct benefits of TPM Indirect benefits of TPM : Achieve goals by working as team. Horizontal deployment of a new concept in all areas of the organization. Share knowledge and experience. The workers get a feeling of owning the machine. Indirect benefits of TPM : Bath Tub Curve 1975 - Weibull Analysis Advantages : 1975 - Weibull Analysis Advantages Provides reasonably accurate failure analysis and failure forecasts with extremely small samples. Provides a simple and useful graphical plot of the failure data. 1986 – Six Sigma : 1986 – Six Sigma Integrated TPM model and Six Sigma concept leads to an improved model of the maintenance process. It uses all advantages of the TPM approach Enables reduction of variations in the process Eliminates the occurrence of errors Reduces the time cycle of the maintenance process Maintenance in IT Environment : Maintenance in IT Environment IT System Maintenance shall be performed for the following reasons: To correct errors To keep system current To improve the system Why Software/Hardware Maintenance ? : Why Software/Hardware Maintenance ? To provide continuity of service To support mandatory upgrades To support user requests for improvements To facilitate future maintenance works Data Backup Quick Recap : Quick Recap Maintenance Decision Diagram : Maintenance Decision Diagram Challenges facing Modern Maintenance : Challenges facing Modern Maintenance Selection of most appropriate techniques Dealing with each type of failure process Fulfilling the expectations of the owners and users Cost-effective & enduring maintenance Involvement & active participation of all persons concerned and connected Changing maintenance techniques at present : Changing maintenance techniques at present Condition monitoring of equipment developed Machines design based on reliability and maintainability Hazard studies carried out Small fast computers & systems came into existence Failure mode and effects analysis (FMEA) developed Multi-skilling & team work became the goal and practice Need based training program e.g. Industrial basic training, TPM, TQM, Quality circle, 5-S became popular Management of Maintenance : Management of Maintenance Monitor the work progress daily, weekly or monthly Identify any significant variance in following through exception reporting. Labor hours Work order costs Total maintenance cost asset Develop alternative solutions or actions to reduce time and costs. : THANK YOU ! You do not have the permission to view this presentation. In order to view it, please contact the author of the presentation.