machine maintenance methodology

8/9/2019 Machine Maintenance Methodology

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A

LIVE PROJECT ON

METHODOLOGY OF MACHINE MAINTENANCE ADOPTED BY

MANUFACTURING COMPANY

COMPANY NAME : GUJARAT ALKALIES & CHEMICALS LTD.

(PROMOTED BY GOVT OF GUJARAT)

PRESENTED BY:

JASKARAN SINGH

DHAVAL SHUKLA


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Maintenance


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WHAT IS MAINTENANCE ?

WHAT IS MAINTENANCE ?

y The activity carried out to prevent the occurrence of

failure and activity carried out after failure to rectify the

defect is called maintenance.

y The primary objective of maintenance is to increase the

operational reliability and personnel safety at minimum

cost.

y Failures are inevitable due to natural wear and tear.


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Vicious Circle for Maintenance

DeptLubrication & Routine

maintenance get neglected

P.M. Schedule not

implemented

More Breakdown More

Downtime Less

Production

Short sighted emphasis on

Downtime reduction

Maintenance Dept.given credit

for attending Breakdowns (Not

preventing them)

Fire fighting to achieve

Downtime Target at any

cost


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y GACL IS USING TWO TYPES OF MACHINERIES

MACHINERIES USED BY GACL

MACHINERIES USED BY GACL

STATIC

PRESSUR VASEL

TANKS

COLUMNS

PIPING

BOILER

DYNAMIC

PUMPS

COMPRESSORS

FANS


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WORKING OF MAINTENANCE DEPARTMENTWORKING OF MAINTENANCE DEPARTMENT


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Ty pes of Maintenance

y Main Types of Maintenance are:

Routine

Maintenance

Preventive

Maintenance

Predictive

Maintenance

Break Down

Maintenance

Shut Down

Maintenance

Opportunity

Maintenance

Types of Maintenance


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Routine Maintenance

y It involves minor jobs s c as Cleaning,L brication, Minor a j stments, Tig tening looseparts, etc.

y

Inspection of earings, V-belts, Fo n ationolts, eart ing, rotective covers, etc.

y If any efect is fo n , it is atten e on t espot or in t e next available s t o n.

y It nee s very little time & money & yet, it paysmaxim m ret rns in prevention of brea o n.


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Preventive Maintenancey Base on c ec lists ic in icate t e etaile

steps of t e job to be one on t e eq ipmenteven ile it is r nning accor ing to t esc e le.

y It is roactive approac of t e maintenanceepartment.


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Predictive Maintenancey Maintaining t e eq ipment before t e brea o n

act ally occ rs, base on t e analysis of t eata obtaine by virt e con ition monitoringsing mo ern scientific instr ments.


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Breakdown Maintenance

y Maintaining t e eq ipment after it as faile .

y

Zero brea o n is li e a g i ing pole star. Wecan never reac it, b t e can c art o r co rseto move to ar s it gra ally.


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Shutdown Maintenancey Maintenance of t e eq ipments by aving

complete s t o n of t e plant stoppingpro ction t ereby.

y Very ell planne in a vance.

y Us ally carrie o t once or t ice in a year asper req irement.


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Opportunity Maintenancey Maintaining t e eq ipment on ic some small

errors / nee for corrections ave beenobserve .

y By oing t is job t e opport nity of s ens t o n can be eliminate .


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PREVENTIVE MAINTENANCE CHART

Name of

Item,

Equipment or

Device and

description

of

Maintenance,

if needed.

Weekly checks

Monthly

Checks

Discrepancies/ Notes

Week 1 Week 2 Week 3 Week 4


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Role of MaintenanceRole of Maintenance

y The frequent failures cause frequent interruption in the

production and the plant and machines become

unreliable. This degree of uncertainty in production due

to machines failures is termed as reliability .

y Higher the reliability in operation lesser will be the

failure or vice versa.


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RE A CT IV E PRE V E N T IV E PRE DICT IV E

COST

BE N E F IT


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Inspection

yy PROPERPROPERINSPECTIONINSPECTIONAT ALL LEVELSAT ALL LEVELS

IMPROVES THEIMPROVES THEQUALITY OFQUALITY OFMAINTENANCE.MAINTENANCE.

machine maintenance methodology

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