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Advanced Maintenance Management

Jose K Puthur RCBS

Jose K Puthur

•BE Electrical and Electronics (NIT Trichy)•MBA FDP (IIM A)•Worked as Customer Engineer/ Sr Engineer in HCL

Infosystems 4 years•National Informatics centre •Systems Engineer/Sr systems Engineer/Principal

Systems Engineer/Technical Director/State Informatics officer – 20 years

•In Rajagiri from 2009 •Doing PhD in E-Business/Bharathiar CBE

Maintenance Definition

British Standard Glossary of terms (3811:1993) defined maintenance as:

The combination of all technical and administrative actions, including supervision

actions, intended to retain an item in, or restore it to, a state in which it can perform a required

function.

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.

Doctor’s Day

The Doctor's Day is celebrated on July 1 all across India to honour the legendary physician and the second Chief Minister of West Bengal, Dr Bidhan Chandra Roy. He was born on July 1, 1882 and died on the same date in 1962, aged 80 years. Dr Roy was honoured with the country's highest civilian award, Bharat Ratna on February 4, 1961.

Raghuram Rajan

he graduated from the Indian Institute of Technology, Delhi with a bachelor's degree in electrical engineering, and he completed the Post Graduate Diploma in Business Administration at the Indian Institute of Management Ahmedabad in 1987. Rajan was a gold medalist in IIT Delhi and IIM Ahmedabad. He received a PhD in management[2] from the Massachusetts Institute of Technology (MIT) in 1991

Chief Economic Adviser to the Government of India.

The rupee fell to a record low on Monday as an emerging markets selloff after strong

US jobs data laid bare the currency's vulnerability and dependence on capital

inflows to fund its record current account deficit.

The rupee was at 61.09, breaching the previous low of 60.76 hit on June 26.

It had closed at 60.225/235 on Friday.Bond yields also jumped on fears that

foreign investors would continue to sell rupee debt.

The 10-year yield rose as much as 13 basis points to 7.63 pct from its previous

close.

Maintenance Activities

Activities of maintenance function could be either repair or replacement activities, which are necessary for an item to reach its acceptable productivity condition and these activities, should be carried out with a minimum possible cost.

Maintenance History

1. In the period of pre-World War II, people thought of maintenance as an added cost to the plant which

did not increase the value of finished product.

Therefore, the maintenance at that era was restricted to fixing the unit when it breaks because

it was the cheapest alternative

Maintenance History

2. During and after World War II at the time when the advances of engineering and scientific technology developed, people developed other types of maintenance, which were much cheaper such as preventive maintenance.

In addition, people in this era classified maintenance as a function of the production system.

•Breakdown Maintenance or Operate to Failure or Unplanned Maintenance

•Preventive or Scheduled Maintenance •Predictive or Condition Based

Maintenance •Opportunity Maintenance •

•Motor car•Bike•Air condition unit•Fridge•House•Water supply system•Computer

•Road•Electric Motor•Bus•Kitchen•Gas stove•Your hostel room•Lathe

•UPS/Inverter•Train• Ship•Air craft•Thermal power plant•Electric Generator

Maintenance History

Fix the equipment when it breaks

-Term terotechnology introduced.

-Recognition of need to present equipment failures. -Models for preventive maintenance developed. -Increased awareness

of: -Environment -Safety -Quality-Need for reliable equipment.-Reduction in costs.

Pre-World War II Post-World War II 1980 OnwardsTime

Developm

ent of M

aintenance

Figure 2.2 Maintenance History(Adapted From Shenoy, Bhadury

1998)

Maintenance History

3. Nowadays, increased awareness of such issues as environment safety, quality of product and services makes maintenance one of the most important functions that contribute to the success of the industry.

World-class companies are in continuous need of a very well organised maintenance programme to compete world-wide.

Maintenance Objectives

Maintenance objectives should be consistent with and subordinate to production goals.

The relation between maintenance objectives and production goals is reflected in the action of keeping production machines and facilities in the best possible condition.


• 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.


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


PLANT

MAINTENANCE

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

Figure 2.3 Maintenance Objectives

Integrated maintenance management system

Department•Production

•Material management

•Personnel

Area of Interaction•Reliable/availability/•Quality

•Effective material conservation

•Optimum utilization of work force

Maintenance ObjectiveResult of Poor maintenance

•Increased down time•Poor efficiency•Deterioration of

equipment•Poor quality product•Higher labour costs•Loss of material •Higher production cost•Increased hazards

Benefits of systematic Maintenance

•Reduction in down time•Reduced material•Increased life of the

equipment•Reduction in over time•Optimum inventory of •spare parts•Optimum operational cost•Good product quality

Types of Maintenance

• Run to Failure Maintenance (RTF)

• Preventive Maintenance (PM)

• Corrective Maintenance (CM)

• Improvement Maintenance (IM)

• Predictive Maintenance (PDM)

Run to Failure Maintenance (RTF)

• The required repair, replacement, or restore action performed on a machine or a facility after the occurrence of a failure in order to bring this machine or facility to at least its minimum acceptable condition.

• It is the oldest type of maintenance.


• It is subdivided into two types:– Emergency maintenance: it is carried out as fast

as possible in order to bring a failed machine or facility to a safe and operationally efficient condition.

– Breakdown maintenance: it is performed after the occurrence of an advanced considered failure for which advanced provision has been made in the form of repair method, spares, materials, labour and equipment.


• Disadvantages:

1. Its activities are expensive in terms of both direct and indirect cost.

2. Using this type of maintenance, the occurrence of a failure in a component can cause failures in other components in the same equipment, which leads to low production availability.

3. Its activities are very difficult to plan and schedule in advance.


• This type of maintenance is useful in the following situations:

1. The failure of a component in a system is unpredictable.

2. The cost of performing run to failure maintenance activities is lower than performing other activities of other types of maintenance.

3. The equipment failure priority is too low in order to include the activities of preventing it within the planned maintenance budget.

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.


British Standard 3811:1993 Glossary of terms defined preventive maintenance as:

the maintenance carried out at predetermined intervals or according to prescribed criteria and intended to reduce the probability of failure or the degradation of the functioning and the effects limited.


• The advantage of applying preventive maintenance activities is to satisfy most of maintenance objectives.


• The factors that affect the efficiency of this type of maintenance:

1. The need for an adequate number of staff in the maintenance department in order to perform this type of maintenance.

2. The right choice of production equipment and machinery that is suitable for the working environment and that can tolerate the workload of this environment.

3. The required staff qualifications and skills, which can be gained through training.

4. The support and commitment from executive management to the PM programme.

5. The proper planning and scheduling of PM programme.6. The ability to properly apply the PM programme.


• 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.


• 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.


• 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.

Corrective Maintenance (CM)

• In this type, actions such as repair, replacement, or restore will be carried out after the occurrence of a failure in order to eliminate the source of this failure or reduce the frequency of its occurrence.

In the British Standard 3811:1993 Glossary of terms, corrective maintenance is defined as:

the maintenance carried out after recognition and intended to put an item into a state in which it can perform a required function.


• This type of maintenance is subdivided into three types:

• Remedial maintenance, which is a set of activities that are performed to eliminate the source of failure without interrupting the continuity of the production process.

The way to carry out this type of corrective maintenance is by taking the item to be corrected out of the production line and replacing it with reconditioned item or transferring its workload to its redundancy.


• Deferred maintenance, which is a set of corrective maintenance activities that are not immediately initiated after the occurrence of a failure but are delayed in such a way that will not affect the production process.

• Shutdown corrective maintenance, which is a set of corrective maintenance activities that are performed when the production line is in total stoppage situation.


• The main objectives of corrective maintenance are the maximisation of the effectiveness of all critical plant systems, the elimination of breakdowns, the elimination of unnecessary repair, and the reduction of the deviations from optimum operating conditions.

• The difference between corrective maintenance and preventive maintenance is that for the corrective maintenance, the failure should occur before any corrective action is taken.

• Corrective maintenance is different from run to failure maintenance in that its activities are planned and regularly taken out to keep plant’s machines and equipment in optimum operating condition.


• The way to perform corrective maintenance activities is by conducting four important steps:

1. Fault detection.2. Fault isolation.3. Fault elimination.4. Verification of fault elimination.

In the fault elimination step several actions could be taken such as adjusting, aligning, calibrating, reworking, removing, replacing or renovation.


• Corrective maintenance has several prerequisites in order to be carried out effectively:

1. Accurate identification of incipient problems.2. Effective planning which depends on the skills of the

planners, the availability of well developed maintenance database about standard time to repair, a complete repair procedures, and the required labour skills, specific tools, parts and equipment.

3. Proper repair procedures.4. Adequate time to repair.5. Verification of repair.

Improvement Maintenance (IM)

• It aims at reducing or eliminating entirely the need for maintenance.

• This type of maintenance is subdivided into three types as follows:

1. Design-out maintenance which is a set of activities that are used to eliminate the cause of maintenance, simplify maintenance tasks, or raise machine performance from the maintenance point of view by redesigning those machines and facilities which are vulnerable to frequent occurrence of failure and their long term repair or replacement cost is very expensive.

Improvement Maintenance (IM)

2. Engineering services which includes construction and construction modification, removal and installation, and rearrangement of facilities.

3. Shutdown improvement maintenance, which is a set of improvement maintenance activities that are performed while the production line is in a complete stoppage situation.

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


• 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.


• 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.

Types of MaintenanceMAINTENANCE

UNPLANNED MAINTENANCE

(REACTIVE)

BREAKDOWNEMERGENCY

PLANNED MAINTENANCE (PROACTIVE)

CORRECTIVE MAINTENANCE

REMEDIALDEFERRED

PREDECTIVE MAINTENANCE

CONDITION - BASED

STATISTICAL - BASED

PREVENTIVE MAINTENANCE

ROUTINE RUNNING

DESIGN - OUTENGINEERING SERVICES

WINDOW

IMPROVEMENT MAINTENANCE

SHUTDOWN CORRECTIVE

SHUTDOWN PREVENTIVE

SHUTDOWN IMPROVEMENT

Shutdown Maintenance

OPPORTU-NITY

Figure 2.4 Maintenance Types

Maintenance Planning

•Maintenance planning involves planning ,controlling and recording

how ,when and what jobs are required to be carried out and resources required to

do the jobs in maintaining the assets in an acceptable standard

Components of Maintenance planning

•Envisaging the work to be carried out•Determining the best method to do the job

•Working out a schedule in consultation with the production department

•Deciding the number and type of personnel required.

•Assessing the time required for the job•Arranging spare parts and materials necessary for

the job and provide technical information support.

•Allocating jobs to individuals•Following up and controlling progress of

work•Maintaining records of jobs, spare parts

used as well as costs incurred

Reasons for Mainenance Planning

•To Protect and ensure a ling life of the machinary and building by regular and

adequate mainenance•To provide technical and operational

support to the management and personnel after commissioning

The basic requirement of a planned maintenance system

•1 ,There should be a register of all assets•2 ,there should be a schedule for

•maintenance work•3,There must be a method of ensuring the

completion of scheduled work ie a control •system

•4,There should be a system of recording and analyzing the performance

Asset Register

•1 ,name of the item•2 ,Description/specification•3,Reference numbers of the item -•manufacturer’s suppliers(if any) and user’s•4 ,Location of the item- with provision for

changes if the item is interchangeable with •other items

Asset Register

•5 ,Manufacturer’s /suppliers details•6 ,Procurement/installation date•7 ,Initial cost, depreciation etc•8,Axcillary equipment- pumps, motors etc•Special requiremnets for services –

air ,water,power•Details of items ,which are suitable

substitute

Asset Register

•11 ,availability of operating instructions/spare parts catalogue

•12 ,Inventory of spare parts against each •machine or piece of equipment•13 ,Breakdown and repair cost•14 ,history of the repair/ mantenance

under taken

Overhaul and repair

•1. to examine carefully for faults, necessary repairs, etc.

•2.) Engineering / General Engineering (to make repairs or adjustments to (a car,

machine, etc.)

Overhaul and repair

The Voyager 2 spacecraft is a 722 kg space probe launched by NASA on August

20, 1977 to study the outer Solar System and eventually interstellar space. It was actually launched before Voyager 1, but Voyager 1 moved faster and eventually

passed it .

Voyager 1

Voyager 1 is a 722-kilogram (1,592 lb) space probe launched by NASA on

September 5, 1977 to study the outer Solar System. Operating for 36 years and

23 days as of September 28, the spacecraft communicates with the Deep

Space Network to receive routine commands and return data. At a distance of about 125.75 AU (1.881×1010 km) from the Sun as of 28 September 2013,[it is the

farthest manmade object from Earth.

Replacement Decision

•In case of a major breakdown of equipment when the further repair is not

economical or feasible•In the case when the machine becomes

obsolete•In the case of technology upgradation•For cheaper production

Replacement Decision

•1 ,running cost•2 ,involves large capital expenditure•3 ,wrong decision may lead to reduction in

profit

Cost factors in the replacement study

•Operating cost•Repair and maintenance•Rebuilding cost•Salvage value

Cost factors not to be considered

•Original cost•Money already spent on repair•Unrealistic book value

For new equipment

•Initial cost•Interest on capital•Salvage value at the end of useful life•Cost advantage of improved product•Saving in labour

Methods of replacement studies

•Pay back period method •P=c/r

•P = pay back period in years•C = original capital invested

•r = annual return expected(total annual earning after deducting taxes )

Present value method

MAPI method

•Method has been developed by George Terborgh the director of the Machinery and

• Allied Product Institute Washington •Here the machine which is to be replaced

is called the defender and the new one is called the challenger

•MAPI Chart

In 1949 the Machinery Allied Production Institute in Washington set up a study

committee chaired byGeorge Terborgh to come up with a new

evaluation system for investments aimed at the equipment replacement

problem, which led to a general rule, usually referred to as the MAPI formula,

that allowsfor the determination at a given moment of

the opportuness of replacing an existing plant with a new

plant that has come on the market, called the potential challenger plant.

Even if the MAPI formula has been the focus of criticisms, it offers a general

solution to the equipment replacementproblem that covers a wide range of cases.

Mangalyan: Countdown begins for India’s first Mars mission

•The 56 hours and 30 minutes countdown started as per schedule at 06.08 AM. It is proceeding

smoothly," a spokesman of the Indian Space Research Organisation (ISRO) told PTI over phone

this morning.•Once launched, the satellite is expected to go around

the Earth for 20-25 days, before embarking on a nine-month voyage to the red planet on December 1

and reach the orbit of the Mars on September 24, 2014.

Management of spare Parts

•To successfully plan and schedule the maintenance job, the spare parts should

be available at the right time ie as and when required

•Inventory means capital investment ,personnel, storage facilities,

movement of spares

Management of spares

•Spares parts should be in stock•Easily identifiable•Should be received immediately on

replacement•The spare parts requirement is irregular

hence forecasting is difficult

•Moving parts may fail more compared to stationary area

•SMPS failure rate is high in case of computers

•Company may give more importance to production targets and the availability of

spares may be a problem•High inventory of spare parts locks up a

sizeable amount of capital owing to accumulation of slow and non moving

items and obsolete or surplus stock

Management of spare parts

•1 ,wear & tear spares•2 ,Overhaul spares•3 ,Insurance spares

Wear &tear spare

•These are used to replace parts which are subject to regular wear & tear and require

to be replaced after a definite number of •hours of operation of the equipment

Overhaul spares

•These are used for parts that must be replaced during overhauling as well as

dismantling and reassembly

Insurance spares

•Some parts are generally not subject to wear & tear during operation of the .

Machinery•How ever their spare parts need to be

stored to safeguard against heavy downtime cost in case of breakdown

Insurance spares

•Spares failure can bring the operations to grinding halt

•Normally they are very reliable•Ex transformer conveyor •Few spares should be kept as spares

Non repairable components

•When a component fails it is immediately replaced the replaced component is not

repaired

OREST Software

•Optimal Replacement of Equipment in the •Short Term has been developed

–Based on Weibull distribution

Quality,Reliability,Maintainability & Availability

•Quality•Fitness for use•There is nothing like absolute quality•Manufacturer and customer mutually

understand the level of quality•“desired function for the required time with

out any failure”

Quality

•Fitness for use•The user expect to have the product

performance over a specified period of time under the stated environment

Reliability

•Dependable

•Trustworthy•Mostly expressed fair, good, excellent•But percentage may be a better way

Means of Controlling Quality

•The quality is controlled by controlling•1,Incoming materials•2,Process at the point of production•3,With better maintenance support system•Fig pg 127

Reliability

•Is the ability of an item to perform a required function(without failure)

•Under stated conditions for a stated period of time

Type of Reliability

•1,Reliability of design•2,Reliability of manufacture•3,Reliability of use

Factors affecting Equipment Reliability

•At each stage of Design and Development,Production,Storage and

Transportation and Operation reliability is affected by the methods used

•Fig 128

System reliability

•Series, Parallel, mixed configuration

Reliability Theory

•Reliability theory describes the probability of a system completing its expected

function during an interval of time. It is the basis of reliability engineering, which is an

area of study focused on optimizing the reliability, or probability of successful

functioning, of systems, such as airplanes, linear accelerators, and any other product.

ainstream of probability and statistics. It

Reliability Theory

•It developed apart from the mainstream of probability and statistics. It was originally a

tool to help nineteenth century maritime insurance and life insurance companies compute profitable rates to charge their

customers. Even today, the terms "failure rate" and "hazard rate" are often used

interchangeably

•The failure of mechanical devices such as ships, trains, and cars, is similar in many ways

to the life or death of biological organisms. Statistical models appropriate for any of these

topics are generically called "time-to-event" models. Death or failure is called an "event",

and the goal is to project or forecast the rate of events for a given population or the probability

of an event for an individual.

•When reliability is considered from the perspective of the consumer of a technology or service, actual reliability

measures may differ dramatically from perceived reliability. One bad experience can be magnified in the

mind of the customer, inflating the perceived unreliability of the product. One plane crash where hundreds of

passengers die will immediately instill fear in a large percentage of the flying consumer population, regardless

of actual reliability data about the safety of air travel.•Reliability period of any object is measured within the

durability period of that object.

Parallel

Serial

Parallel

Design for Maintainability

Maintenance Accessibility Evaluation Accessibility is the relative ease with

which a part or piece of equipment can be reached for service ,replacement

or repair. The lack of accessibility is maintainability problem and a frequent cause of ineffective maintenance. The evaluation may also be performed by

assigning to each maintainability criterion, a numerical value between 1 to 5 etc

Maintainability Index

•Used for software •The maintainability index (MI) is a

compound metric designed at the University of Idaho in 1991 by Oman and Hagemeister.

The primary aim of the metric is to determine how easy it will be to maintain a

particular body of code. It's great claim to fame is that it was validated in the field by Hewlett Packard in a fairly extensive trial

Reliability maintainability availability scalability

•In Software

Energy Management and safety Health & Environment

•Electrical •20% to 30% power lost in transmission•Use of proper motor•Operate the transformer in the optimum capacity•Proper insulation of electric furnaces•Use old ,obsolete or defective assets by energy

efficient ones•Use natural lighting as far as possible

» Mechanical Maintain Proper sharpness of toolsProper lubrication of partsPumps with proper matching in terms of head flow and other parametersArrest leakage in water lines and valves

Safety health and the work Environment

•Safety standards•Accidents very costly

Preventive Measures

•Fencing•Boilers and other pressure vessels must

be maintained properly to keep them in proper order

•Proper illumination•Use of protective clothing and gear•Proper training•Tools should be kept in proper place

Reliability Centered Maintenance (RCM)

•Fundamental cause and effect relationship between scheduled maintenance and

• operating reliability This assumption was based on the intuitive belief that because

mechanical parts wear out, the reliabilty ofany equipment is directly related to operating age.

It therefore ,followed hat the more frequently equipment overhauled , the better protected it

was against the likelyhood of failure.

•Nowlan and Heap reached the conclusion that “a maintenance policy based exclusively on some maximum operating age would no matter what

the age limit have little or no effect on the failure rate In separate independent studies ,it was noted that a difference existed between the

perceived and intrinsic design life for the majority of equipments and components . In fact it was

discovered that in many cases equipment greatly exceed the perceived or stated design life

Maintenance Philosophies

Breakdown Maintenance

Industrial Revolution

Preventive or Change-out Maintenance

Second World War

Predictive or Condition

Based Maintenance

Mid ’60’s

Reliability Centred

Maintenance

Mid ’80’s

RCM

•Is the optimum mix of reactive, time or interval-based, condition-based , and

proactive maintenance practices. Fig 100•With the help of computers it is possible to

identify the precursors of failure , quantify equipment condition and schedule the

appropriate repair with a higher degree of confidence

•Each failure mode is analysed through decision-logic to ascertain the type of maintenance needed and its optimum

level

Failure Mode and Effect Analysis (FMEA)

•FMEA is a reliabiliy engineering method(MIL-STD_1629A-1980)

•FMEA is a detailed cause and effect analysis for failures with failure effects

being categorized according to their severity

RCM codes and Standards

•American Society of Non-Destructive Testing (ASNT) Recommended practice Number SNT-TC-

1A•American Society for testing and Materials (ASTM) •ASTM C 1060•ASTM C 1153,E 1186,E 1149•ISO 6781,ISO 3945,•MIL-STD-2194,STD-2173•NAVAIR 00-25-403

RCM•A core process in the development of a maintenance

strategy, SKF's Reliability-Centered Maintenance (RCM) is embedded with FMEA, identifying failure

causes and determining applicable and cost-effective tasks to prevent the failures where asset criticality is

high and optimization of existing maintenance is needed. The process determines what is required for

an asset to keep fulfilling its intended function in its present operating context. RCM is effective in

delivering a roadmap of appropriate tasks, frequencies, man-hours and skills mix .

Tero Technology

BHP’s Experience

•Steel Industry World Wide Review–Man-hours per Liquid Tonne of Steel–Four Best Practice Organisations–Biggest difference – Maintenance treated as a

PROFIT CENTRE•BHP was managing Maintenance as

COST CENTRE

BHP Action Plan

•Understand Problem•Set Overall Target

–Target 40% Reduce in Maint. Cost Per Tonne in 5 years

•Develop Approach for Solution–7 Step Plan

BHP’s 7 Step Plan

.1Re-Education

.2Re-Define Roles & Responsibilities

.3Re-Develop Measurements

.4Provide Processes and Systems

.5Apply Strategy Based Maintenance

.6Formalise Continuous Improvement

.7Focus on Waste Reduction

Total Productive Maintenance(TPM)

•The goal of the TPM program is to markedly increase production while, at the

same time increasing employee morale and job satisfaction.

•In1970 Nakajima applied the principles of team work and empowerment in the form

of autonomous maintenance to productive maintenance

•In western style maintenance approach a centralized maintenance department is

responsible for maintenance of equipment

•Zero breakdown •Zero defect

TPM - Objectives

•1 ,To maximize maintenance effectiveness•2 ,To develop a maintenance system for the

service life of the equipment•3 ,To involve all the departments that plan,

specify, design or maintain the equipment thus it includes all technical, engineering, design

production and maintenance employees •To involve personnel from top management to

personnel on the production floor

•Around 10 to 40 % of the total cost of the product is attributed to maintenance

activities and is considered to be integral part of the business process

TPM implementation statges

•Preparation, introduction, implementation and consolidation

Signature Analysis

•Predictive maintenance system is adopted •near the end of the useful life•Potential failure points detected by various

diagnostic techniques such as vibration noise monitoring,wear particle and temperature

monitoring•Signals received through these machine

health monitoring techniques are grouped under Signature anlysis

•It is similar to ECG in health monitoring•P-F interval is deferent in the case of different

signatures and there fore it is necessary to consider it before selecting a perticular system

of machine health monitoring•Ex vibration monitoring P-F interval 1 to 9

minths•Wear particle analysis 1-6 months•While heat P-F interval may be 1-5 days

•One factor to be considered is the cost of condition monitoring system

•And the criticality of the equipment

•Terotechnology is focused on integrated management of material sources. Its purpose

is to improve the distribution of working sources, from purchase, usage, maintenance and recycling. Terotechnology represents the

technical and economical aspect, providing sufficient background for researching

processes of component faults and system breakdown. Besides it uses advanced

predicting, monitoring and maintenance scheduling algorithms.

Selection of signature technique

•Once various parameters have been identified the best suited parameter for carrying out the signature analysis for

machine health monitoring is to be selected. Best suited but also cost

effective•Exmple of thermometer

System of signal processing/recording

•Reading /recording frequency•Should be put on line•Should be located in a central facility•Training of personnel•They should be educated to identify the

deviation from the normal signature•They should no how to calibrate these

systems

Process of application of condition monitoring

•Detection•Diagnosis•Prognosis•Priscription

Terotechnology

•Terotechnology is an interdisciplinary field, joining mechanical, electrical, diagnostic,

signal processing, and maintenance experts. Student gains sufficient

knowledge to support maintenance of complex mechanical sysems.

Tero Technology

•Economic life –cycle costs approach to management of plant keeping in view the

reliability, maintainability, efficiency and full utilization of the plant, equipment and

building in order to achieve maximum return on investment(ROI)

Factors of tero technology

•Design

•Purchase•Projects

•Operations

•Finance

•For reliability and •Maintainability•Best buy•Easily operable and

maintainable•Reduce down time and

improve care of assets•Cost monitoring ,cost

control

Tero technology

•Records

•Personnel

•Maintain proper records

•Selection and training of operating and

maintenance personnel

Life cycle costing•Acquisition cost•Product distribution cost

•Operating cost•Maintenance cost•Technical data cost•Inventory cost•Training cost•Retirement & disposal

cost

Tero technology

•The designer needs the help of maintenance manager in evolving designs that are less prone to breakdowns and are

easy to maintain

•Development of methods and procedures with regard to maintenance of technical

systems.

VED

•Vital- absence of which will cause stoppage of production

•An item whose procurement in an •emergency will involve very high cost•An item on which many other processes

depend and which will come to standstill in case the item breakdown

•Essential (E items)•Which cause partial stoppage•Moderate losses

Desirable (D)

•Not very significant losses

ABC Analysis

•Items are classified on the basis of annual consumption value

•10 to 15 % items accounts for 70 to 80 % of annual monetary value and they are

classified as ‘A’•This is very important to monitor the

useage

FSN analysis

•F- fast moving•S- slow moving•N- normal moving•Turn over= annual consump/aver •Inventory•It should be more than 4 for F•2 to 4 for normal •0 to 2 for S

•A combination of all three method is followed.

•Category VAF•Vital costly fast moving

•There are relatively fewer items in the spare parts inventory in relation to the

general stores•How ever Economical Order Quantity

(EOQ) may be used

Individual Assignment

•Imagine You are appointed as customer support manager/ maintenance manger

•In a company •Example Blue star ,voltas(A/C)•Maruthi, Ford , Hundai, Honda•HP ,Dell,lenpvo,wipro•IFP,Whirlpool,Samsung•FACT, Cochin refinary, India Cement,Apollo

tyres

•You have to run this as a profit centre•List the set of activities per one week•What are the tools you may use to monitor

the complaints/manpower•Get a copy of the service slip

What is the man power requirement with cost and the skill set details, salary etc

What all spare you should have?

•What is the type of Preventive maintenance you will plan?

•Give your financial projection for the year 2013- 14

•What is your down time target? •How you are planning to reach that level? •What is your new installation plan?

•Are you going for per call basis or Annual Maintenance plan?

•What is rate you charge in each case?

Failure Data Analysis

•Design consideration•Maintenance cost consideration•Maintenance staff consideration

Replacement decision

•Cost of a machine is Rs 6100/- and its scrap value is Rs 100/-.Pas record of

• maintenance cost is given below

BATH-TUB CURVE

MTTF

•mean time to failure

•The first part is a decreasing failure rate, known as early failures.

•The second part is a constant failure rate, known as random failures.

•The third part is an increasing failure rate, known as wear-out failures.

Breakdown time distribution

•Poisson’s•Normal •Exponential

Normal distribution

Poisson’s Distribution

amm

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