maintenance genesis presentation

8/7/2019 Maintenance Genesis Presentation

1/44


2/44

Group 2- Members

1. Richa KH2009SMBA18P038

2. Venkatesh KH2009SMBA18P054

3. Diptesh KH2009SMBA18P0664. Jasmeet KH2009SMBA18P070

5. Ramya KH2009SMBA18P101

6. Ankur KH2009SMBA18P104


3/44


4/44

Genesis A beginning or origin of anything

Maintenance It is the work of keeping something in proper

condition

Maintenance Genesis


5/44

Breakdown Consequences

Pr

oduction capacity isr

educedOrders are delayed

Noproduction

Overhead continues

Cost per unit increases

Quality issues

Product may be damaged

Safety issues

Injury to employees

Injury to customers


6/44

GoalofMaintenance

To keep production systems in good workingcondition 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 costsTo maintain high quality

To avoid missed delivery dates


7/44

Availability

ReliabilityProbability that the item will not fail

MaintainabilityThe 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


8/44

Maintenance Management Prior to World War II

Reactive MaintenanceBreakdown maintenance

Reactive approach

Dealing with breakdowns or problems whenthey occur

Challenges :

Poor planning

Incomplete repair


9/44

Maintenance Management Post World War II


10/44

Preventive MaintenanceTo prevent the failure of equipment before it actually

occurs through:

Periodic maintenance ( Time based maintenance -

TBM)

Predictive maintenance

Year - 1950


11/44

Time basedmaintenance (TBM)

Servicing and cleaning equipment

Inspection

Oiling

Replacing parts

Periodic maintenance


12/44

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


13/44

Toassess machinery condition it uses:

Non destructive testing techniques

Visual inspection

Performance data

Ultimate Goal ofCBM:Eliminate routine maintenance

Service equipment only when monitoring system

indicates

Key components of CBM:

Vibration monitoring

Thermography

Oil analysis

Condition Based Maintenance (CBM)


14/44

Monitors frequencies to predict impending defect

Compares the vibration spectra of new equipment vs.

subject equipment

Vibration monitoring


15/44

Analysis of thermal information by using non contact

thermal imaging devices.

Thermography

Worn refractory insulation causing hotspot


16/44

Detecting the presence of contamination in oil.

Example:

Electrical transformers oil analyzed for thepresence of carbon deposits

Analyzing High Engine Oil consumption

Oil Analysis


17/44

Improved system reliability.Decreased cost of replacement.

Decreased system downtime.

Better spares inventory management.

Benefits of preventive maintenance


18/44

Condition 1:

The component in question has an increasing failure rate.

Condition 2:

The overall cost of the preventive maintenance action

must be less than the overall cost of a corrective action

When Does Preventive Maintenance Make Sense


19/44

Quick Recap


20/44

Equipment with design weakness must be redesigned toimprove:

Reliability

Maintainability

Preventive Maintenance

Analyzing techniques:

FMEA

Root cause analysis

1957 - Corrective Maintenance


21/44

A methodology to analyze and discover:

All potential failure modes of a system

The effects these failures have on the system

How to correct and or mitigate the failures or effects

on the system.

Failure Mode andEffects Analysis


22/44


23/44

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!


24/44

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


25/44

Preventive

maintenance

+

Maintenance prevention = Productive maintenance

+

Maintainability Improvement

Maximize plant and equipment effectiveness

Achieve optimum life cycle cost of

production equipment.

1963 - Productive Maintenance


26/44

1971 - Total Productive Maintenance


27/44

Adoption of life cycle approach ,improving the overall performance

of production equipment.

Improving productivity by highly motivated workers ,achieved by

job enlargement.

The use ofvoluntary small group activities for identifying the cause

of failure, possible plant and equipment modifications.

Motives ofTPM


28/44

The concept of "I (Production operators) Operate, You

( Maintenance department ) fix" is not followed.

Uniqueness ofTPM


29/44

Zero Defects Zero Breakdown

Zero accidents

Involve people in all levels of organization.

TPM Objectives


30/44

Obtain Minimum 80% OPE

Obtain Minimum 90% OEE

Rectify customer complaints.

Reduce the manufacturing cost by 30%.

Satisfy the customers needs by 100 %

Reduce accidents.

Follow pollution control measures.

Direct benefits ofTPM


31/44

Higher confidence level among the employees.

Keep the work place clean, neat and attractive.

Favorable change in the attitude of the operators.

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 ofTPM


32/44

Bath Tub Curve


33/44

1975 - Life DataAnalysis (WeibullAnalysis)

Leading method in the world for fitting life data.The three-parameter Weibulls expression is given by:

Where,

= scale parameter,

= shape parameter (or slope),

= location parameter.


34/44

WeibullAnalysis Advantages

Provides reasonably accurate failure analysis andfailure forecasts with extremely small samples.

Provides a simple and useful graphical plot of the

failure data.


35/44

< 1

Implies infant mortality

= 1

Implies failures are

random

An oldpart is as goodas

a newpar

t1 3

Implies rapidwearout in

oldage

Occurs for:

Wear-through

Weibull Interpretation


36/44


37/44

Maintenance in IT Environment

IT

System Maintenance shall be performed for thefollowing reasons:

To correct errors

To keep system current

To improve the system


38/44

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


39/44

Maintenance Decision Diagram


40/44

Maintenance Strategy Model


41/44

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


42/44

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


43/44

Management ofMaintenance

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.


44/44

THANK YOU !

maintenance genesis presentation

Documents