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MAINTENANCE AND RELIABILITY ENGINEERING - Lecture 1

The document discusses different types of maintenance strategies used to keep equipment running properly and minimize downtime. It describes corrective, scheduled, preventive, and predictive maintenance. The goals of maintenance are to maximize equipment performance, prevent failures, minimize production losses, and increase safety. Maintenance is important for both manufacturing and service industries to improve productivity, quality, and profitability.

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K ULAGANATHAN
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470 views24 pages

MAINTENANCE AND RELIABILITY ENGINEERING - Lecture 1

The document discusses different types of maintenance strategies used to keep equipment running properly and minimize downtime. It describes corrective, scheduled, preventive, and predictive maintenance. The goals of maintenance are to maximize equipment performance, prevent failures, minimize production losses, and increase safety. Maintenance is important for both manufacturing and service industries to improve productivity, quality, and profitability.

Uploaded by

K ULAGANATHAN
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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P18IEE3018 MAINTENANCE AND RELIABILITY

ENGINEERING
Introduction to Maintenance
Imagine

• MAS flight Boeing 737 left KLIA at 4.00 am

• All two engines, hydraulic systems working

• 4.30 am explosion shock plane

• Number 2 engine torn apart; 2 separate hydraulic lines ceased to work

• In spite of maintenance work, engine still failed

• Imagine having no maintenance system


• Maintenance and reliability is important

• Maintenance and product quality

• Maintenance and productivity

• Maintenance and safety

• Maintenance and supply chain, JIT

• Failure cause disruption, waste, accident, inconvenience


and expensive
• Operators less able to do repairs themselves

• Machine and product failure can have effect on


company’s operation and profitability

• Idle workers, facility

• Losses due to breakdown


Failure
• Failure – inability to produce work in appropriate manner
• Equipment / machine failure on production floor – worn out
bearing, pump, pressure leaks, broken shaft, overheated machine
etc.
• Equipment failure in office – failure of power supply, air-
conditioned system, computer network, photocopy machine
• Vehicle failure – brake, transmission, engine, cooling system
Maintenance in Service Industry
• Hospital
• Restaurants
• Transport companies
• Banks
• Hotels and resorts
• Shopping malls / retail
• Gas station
Maintenance in Manufacturing Companies
• Electronic
• Automotive
• Petrochemicals
• Refinery
• Furniture
• Ceramics
• Food and beverages
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


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

• 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

• 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

• 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:
• 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

• Must be consistent with the goals of production (cost, quality,


delivery, safety)

• Must be comprehensive and include specific responsibilities


Maintenance Costs
• Cost to replace or repair

• Losses of output

• Delayed shipment

• Scrap and rework


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


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 Breakdown 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 equipment's regulated by statutory provisions e.g.
cranes, lift and hoists etc.
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)

• Principle – “Prevention is better than cure”


• Procedure - Stitch-in-time
• It locates weak spots of machinery and equipment's
• It provides them periodic/scheduled inspections and minor
repairs to reduce the danger of unanticipated breakdowns
Advantages of PM
• 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 equipment's and spare parts
• Better product quality and fewer reworks and scraps
• Increases plant life
• Increases chances to get production incentive bonus
Predictive (Condition-based) Maintenance
• In predictive maintenance, machinery conditions are periodically
monitored, and this enables the maintenance crews to take timely
actions, such as machine adjustment, repair or overhaul
• It makes use of human sense and other sensitive instruments, such as
• audio gauge, vibration analyzer, amplitude meter, pressure, temperature and
resistance strain gauges etc.
Predictive Maintenance (Contd.)

• Unusual sounds coming out of a rotating equipment predicts a


trouble
• An excessively hot electric cable predicts a trouble
• Simple hand touch can point out many unusual equipment
conditions and thus predicts a trouble

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