L1

• Maintenance engineering is the management, control, execution and quality of those activities which ensure the optimum levels of availability and overall performance of plant and equipment
• Objectives of maintenance


  • Profitability
  • Quality
  • Safety
• Main categories of maintenance


  • Developing a maintenance policy to support business objectives
  • Improvement maintenance
  • Breakdown maintenance
  • Preventive maintenance
  • Predictive maintenance
  • Proactive maintenance

  
• Maintenance policy


  Policy which must reflect the differing needs within a particular company to support business, marketing and manufacturing strategy

  
• Factors that maintenance policy depends on

  • Plant and equipment availability
  • Reliability
  • Continuity
  • Quality
  • Health and safety
  • Environment
  • Costs
  • Level of technology being used
• Modes of machinery deterioration and failure


  • Early life failure
  • Random failure
  • Wear out failure
• Failure analysis procedure


  Determine the cause of a failure
• Advances in maintenance concept


  • Reliability centered maintenance (RCM) process
  • Failure mode effects & criticality analysis (FMECA)
  • Fault tree analysis (FTA)
  • Total productive maintenance (TPM)

  
• Reliability centered maintenance (RCM) process is used to determine particular maintenance to be performed

  
• Failure mode effects & criticality analysis (FMECA) and Fault tree analysis (FTA) are used to identify root causes of failure models
• Total productive maintenance (TPM) is for the systematic elimination of the causes of equipment failure using a people-oriented approach to resolve problems at source
• Module intended learning outcomes (MILOs)


  • Devise a maintenance procedure and a management strategy for engineering plant and equipment in the workplace
  • Classify the modes of machinery deterioration and failure and assess failure characteristics
  • Apply the standard procedure and techniques in carrying out a failure analysis of a failed component
  • Organize and plan human and technological resources for maintenance
  • Apply systematic elimination of the causes of equipment failure using a people-oriented approach to resolve problems at source
• Teaching and learning activities (TLAs)


  • Lecture
  • Tutorial
  • Industrial visits/Guest lecture
• Assessment tasks/activities


  • University examination
  • One class test
  • Two assignments
  • One case study
• Maintenance includes all actions necessary for retaining a system or product in, or restoring to a desired operational state

  
• Objectives of maintenance


  • Enable product quality and customer satisfaction to be achieved through correctly adjusted, serviced and operated equipment
  • Maximize the useful life of the equipment
  • Keep equipment safe and prevent the development of safety hazards
  • Minimize the total production costs directly attributable to equipment service and repair
  • Minimize the frequency and severity of interruptions to operating processes
  • Maximize production capacity from the given equipment resources
• A maintenance service is important to keep equipment in running order and to reduce the number of breakdowns
• Reasons why breakdowns can be expensive


  • Need for intervention in manufacturing or other processes
  • Investigation and repair
  • Lowered quality of the product
  • Failure to meet fixed costs
  • Variable costs not otherwise allowed for
  • Extra costs incurred in compensating for loss of production
  • Reduced profit margin
• Maintenance department functions


  • Planning and repairing equipment/facilities to acceptable standards
  • Performing preventive maintenance
  • Preparing realistic budgets
  • Managing inventory
  • Keeping records on equipment, services, etc.
  • Developing effective approaches to monitor the activities of maintenance staff
  • Developing effective techniques for keeping operations personnel, upper-level management, and other concerned groups aware of maintenance activities
  • Training maintenance staff and other concerned individuals
  • Reviewing plans for new facilities, installation of new equipment etc.
  • Implementing methods to improve workplace safety and developing safety education-related programs for maintenance staff
  • Developing contract specifications and inspecting work performed by contractors

  
• Nine-step approach for managing a maintenance program effectively


  • Identify existing deficiencies
  • Set maintenance goals
  • Establish priorities
  • Establish performance measurement parameters
  • Establish short- and long-range plans
  • Document both long and short-range plans
  • Implement plan
  • Report status
  • Examine progress annually
• Elements of effective maintenance management


  • Maintenance policy
  • Material control
  • Work order system
  • Equipment records
  • Preventive and Corrective maintenance
  • Job planning and scheduling
  • Backlog control and priority system
  • Performance measurement

  
• Maintenance policy


  One of the most important elements of effective maintenance management, essential for continuity of operations and a clear understanding of the maintenance management program

  
• Material control


  Efficient utilization of personnel depends largely on effectiveness in material coordination
• Work order system


  Authorizes and directs an individual or a group to perform a given task, useful for management in controlling costs and evaluating job performance
• Equipment records


  Play a critical role in effectiveness and efficiency of the maintenance organization, useful for procuring new items/equipment, troubleshooting breakdowns, making replacement or modification decisions, investigating incidents, identifying areas of concern, performing reliability and maintainability studies, and conducting life cycle cost and design studies
• Preventive and corrective maintenance


  Preventive maintenance keeps facility/equipment in satisfactory condition through inspection and correction of early-stage deficiencies, corrective maintenance is an important factor in the effectiveness of maintenance organization

  
• Job planning and scheduling


  Job planning is an essential element, formal planning should cover 80 to 85% of the maintenance workload, scheduling is as important as job planning and effectiveness is based on the reliability of the planning function
• Backlog control and priority system


  Identification of backlogs is important to balance manpower and workload requirements, determination of job priority is necessary to consider factors such as importance of the item or system, the type of maintenance, required due dates, and the length of time the job awaiting scheduling will take
• Performance measurement


  Successful maintenance organizations regularly measure their performance through various means, performance analyses contribute to maintenance department efficiency and are essential to revealing the downtime of equipment, peculiarities in operational behavior of the concerned organization, developing plans for future maintenance

  
• Primary functions of maintenance engineering

  • Maintenance of existing plant equipment
  • Maintenance of existing plant buildings and grounds
  • Equipment inspection and lubrication
  • Utilities generation and distribution
  • Alterations to existing equipment and buildings
  • New installations of equipment and buildings
• Secondary functions of maintenance engineering


  • Storekeeping
  • Plant protection, including fire
  • Waste disposal
  • Salvage
  • Insurance administration
  • Janitorial (caretaker) service
  • Property accounting
  • Pollution and noise abatement
  • Any other service delegated to maintenance engineering by plant management