Category: Education

Presentation Description

About Maintenance, Maintenance Definition, Maintenance in Service Industry, Maintenance in Manufacturing Companies, Types of Maintenance etc.


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R.C.T.I. MAINTENANCE PREPARED BY :- (1) HARSH B. PATEL - 126400319032 (2) PRATIK D. PATEL - 126400319039 (3) RAHUL G. RAJ - 126400319037 GUIDED BY :- D. P. PATEL



Maintenance Definition:

Maintenance Definition maintenance is a set of organised activities that are carried out in order to keep an item in its best operational condition with minimum cost acquired.


Maintenance All actions necessary for retaining an item, or restoring to it, a serviceable condition, include servicing, repair, modification, overhaul, inspection and condition verification Increase availability of a system Keep system’s equipment in working order

Maintenance in Service Industry:

Maintenance in Service Industry Hospital Restaurants Transport companies Banks Hotels and resorts Shopping malls / retail Gas station

Maintenance in Manufacturing Companies:

Maintenance in Manufacturing Companies Electronic Automotive Petrochemicals Refinery Furniture Ceramics Food and beverages


Question? Why do we need maintenance? What are the costs of doing maintenance? What are the costs of not doing maintenance? What are the benefits of maintenance? How can maintenance increase profitability of company?

Purpose of Maintenance:

Purpose of Maintenance Attempt to maximize performance of production equipment efficiently and regularly Prevent breakdown or failures Minimize production loss from failures Increase reliability of the operating systems

Principle Objectives in Maintenance:

Principle Objectives in Maintenance To achieve product quality and customer satisfaction through adjusted and serviced equipment Maximize useful life of equipment Keep equipment safe and prevent safety hazards Minimize frequency and severity of interruptions Maximize production capacity – through high utilization of facility

Problems in Maintenance:

Problems in Maintenance Lack of management attention to maintenance Little participation by accounting in analyzing and reporting costs Difficulties in applying quantitative analysis Difficulties in obtaining time and cost estimates for maintenance works Difficulties in measuring performance

Problems Exist Due To::

Problems Exist Due To: Failure to develop written objectives and policy Inadequate budgetary control Inadequate control procedures for work order, service requests etc. Infrequent use of standards To control maintenance work Absence of cost reports to aid maintenance planning and control system

Maintenance Objectives:

Maintenance Objectives Maximising production or increasing facilities availability at the lowest cost and at the highest quality and safety standards. Reducing breakdowns and emergency shutdowns. Optimising resources utilisation. Reducing downtime. Improving spares stock control.

Maintenance Objectives :

Maintenance Objectives Improving equipment efficiency and reducing scrap rate. Minimising energy usage. Optimising the useful life of equipment. Providing reliable cost and budgetary control. Identifying and implementing cost reductions.

Maintenance Objectives :

Maintenance Objectives PLANT M A I N T E N A N C E Reduce Breakdowns Reduce Downtime Improving Equipment Efficiency Improving Inventory Control Implementing Cost Reduction Maximising Production Optimising Resources Utilisation Optimising Useful Life of Equipment Minimising Energy Usage Providing Budgetary Control

Maintenance Costs:

Maintenance Costs Cost to replace or repair Losses of output Delayed shipment Scrap and rework

Types of Maintenance:

Types of Maintenance Maintenance may be classified into four categories: (some authors prefer three categories- scheduled and preventive maintenances are merged) Corrective or Breakdown maintenance Scheduled maintenance Preventive maintenance Predictive (Condition-based) maintenance

Corrective or Breakdown Maintenance:

Corrective or Breakdown Maintenance Corrective or Breakdown maintenance implies that repairs are made after the equipment is failed and can not perform its normal function anymore Quite justified in small factories where: Down times are non-critical and repair costs are less than other type of maintenance Financial justification for scheduling are not felt

Disadvantages of Corrective Maintenance:

Disadvantages of Corrective Maintenance Breakdown generally occurs inappropriate times leading to poor and hurried maintenance Excessive delay in production & reduces output Faster plant deterioration Increases chances of accidents and less safety for both workers and machines More spoilt materials Direct loss of profit Can not be employed for equipments regulated by statutory provisions e.g. cranes, lift and hoists etc

Scheduled Maintenance:

Scheduled Maintenance Scheduled maintenance is a stitch-in-time procedure and incorporates inspection lubrication repair and overhaul of equipments If neglected can result in breakdown Generally followed for: overhauling of machines changing of heavy equipment oils cleaning of water and other tanks etc.

Preventive Maintenance (PM):

Preventive Maintenance (PM) It is a set of activities that are performed on plant equipment, machinery, and systems before the occurrence of a failure in order to protect them and to prevent or eliminate any degradation in their operating conditions.

Preventive Maintenance (PM):

Preventive Maintenance (PM) The factors that affect the efficiency of this type of maintenance: The need for an adequate number of staff in the maintenance department in order to perform this type of maintenance. The right choice of production equipment and machinery that is suitable for the working environment and that can tolerate the workload of this environment. The required staff qualifications and skills, which can be gained through training. The support and commitment from executive management to the PM programme. The proper planning and scheduling of PM programme. The ability to properly apply the PM programme.

Preventive Maintenance (PM):

Preventive Maintenance (PM) It is good for those machines and facilities which their failure would cause serious production losses. Its aim is to maintain machines and facilities in such a condition that breakdowns and emergency repairs are minimised. Its activities include replacements, adjustments, major overhauls, inspections and lubrications.

Preventive Maintenance (PM):

Preventive Maintenance (PM) Researchers subdivided preventive maintenance into different kinds according to the nature of its activities: Routine maintenance which includes those maintenance activities that are repetitive and periodic in nature such as lubrication, cleaning, and small adjustment. Running maintenance which includes those maintenance activities 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 take place.

Preventive Maintenance (PM):

Preventive Maintenance (PM) Opportunity maintenance which is a set of maintenance activities that are performed on a machine or a facility when an unplanned opportunity exists during the period of performing planned maintenance activities to other machines or facilities. Window maintenance which is a set of activities that are carried out when a machine or equipment is not required for a definite period of time. Shutdown preventive maintenance , which is a set of preventive maintenance activities that are carried out when the production line is in total stoppage situation.

Advantages Preventive Maintenance :

Advantages Preventive Maintenance Advantages: Reduces break down and thereby down time Lass odd-time repair and reduces over time of crews Greater safety of workers Lower maintenance and repair costs Less stand-by equipments and spare parts Better product quality and fewer reworks and scraps Increases plant life Increases chances to get production incentive bonus

Predictive Maintenance (PDM):

Predictive Maintenance (PDM) Predictive maintenance is a set of activities that detect changes in the physical condition of equipment (signs of failure) in order to carry out the appropriate maintenance work for maximising the service life of equipment without increasing the risk of failure. It is classified into two kinds according to the methods of detecting the signs of failure: Condition-based predictive maintenance Statistical-based predictive maintenance

Predictive Maintenance (PDM):

Predictive Maintenance (PDM) Condition-based predictive maintenance depends on continuous or periodic condition monitoring equipment to detect the signs of failure. Statistical-based predictive maintenance depends on statistical data from the meticulous recording of the stoppages of the in-plant items and components in order to develop models for predicting failures.

Predictive Maintenance (PDM):

Predictive Maintenance (PDM) The drawback of predictive maintenance is that it depends heavily on information and the correct interpretation of the information. Some researchers classified predictive maintenance as a type of preventive maintenance. The main difference between preventive maintenance and predictive maintenance is that predictive maintenance uses monitoring the condition of machines or equipment to determine the actual mean time to failure whereas preventive maintenance depends on industrial average life statistics.

Maintenance Costs:

Maintenance Costs Maintenance Commitment Cost Breakdown Cost

Maintenance Costs:

Maintenance Costs Maintenance Commitment Cost PM Cost Breakdown Cost

Maintenance Costs:

Maintenance Costs Maintenance Commitment Cost PM Cost Breakdown Cost Total Maintenance Cost

Maintenance Costs:

Maintenance Costs Maintenance Commitment Cost PM Cost Total Maintenance Cost Breakdown Cost Optimal



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