1. INTRODUCTION Maintenance has traditionally been considered as a support, non-productive and nonvalue adding function of business.

Maintenance has become more challenging in the current dynamic business environment. Itis considered one of the important strategic decisions in operations management. Traditionally, maintenance, with its multifaceted activities, resources, measurement, and management, has been important to manufacturing organizations. However, in recent years, the need to manage the different facets of maintenance more effectively has gained added importance due to changing operational technologies, and the changing organizational role of maintenance Maintenance involves maintaining and securing the equipment and systems in, or restoring them to, a state in which they can perform the required functions. The reason why maintenance is considered a cost-controlled activity is that engineers and technical men found it difficult to measure the investments on maintenance in total economic terms. It is very easy to find the cost of maintenance but difficult to quantify the results. i!e an iceberg, where the biggest part is invisible under the water and only a small part visible above the surface. The visible part represents the direct maintenance e"pense while the invisible part silently denotes the various factors influenced by maintenance. The maintenance function is inherent to production. #ven so, understanding and quantifying maintenance activities can be problematic. $ recent understanding is that maintenance is more than a group of people or a wor!shop and transcends the limits of a traditional department. 1.1 Relationship of maintenance practices with manufacturing organisation. Maintenance is normally perceived to have a poorer rate of return than any other ma%or budget item. &et, most companies can reduce maintenance costs by at least one-third, and improve the level of productivity, by giving maintenance the management priority it requires. That priority must span all levels of an organization's management structure to develop an understanding at each level of the significance maintenance can have upon the success or failure of organization ob%ectives. The maintenance processes can be streamlined to eliminate waste and produce brea!through performance in areas valued by customers. The

potential impact of maintenance on the manufacturing performance is substantial. Maintenance is responsible for controlling the cost of manpower, material, tools, and overhead. In financial terms, maintenance can represent )* to +* per cent of the value added to a product as it moves through the plant. ,urther, a survey of manufacturers found that full-time maintenance personnel as a percentage of plant employees averaged (-.. per cent of overall staffing in a study involving manufacturing organizations, whereas in refineries, the maintenance and operations departments are often the largest and each may comprise about /* per cent of total staffing.The effectiveness of maintenance function significantly contributes towards the performance of equipment, production and products. In the dynamic and highly challenging environment, reliable manufacturing equipment is regarded as the ma%or contributor to the performance and profitability of manufacturing systems. Its importance is rather increasing in the growing advanced manufacturing technology application stages. Therefore, equipment maintenance is an indispensable function in a manufacturing #nterprise. The recent competitive trends and ever increasing business pressures have been putting maintenance function under the spotlight as never before. ,or maintenance to ma!e its proper contribution to profits, productivity, and quality, it must be recognized as an integral part of the plant production strategy. Thus achieving e"cellence in maintenance issues has to be treated as a strategic issue for manufacturing organizations to create worldclass-manufacturers. The effective integration of maintenance function with engineering and other manufacturing functions in the organization can help to save huge amounts of time, money and other useful resources in dealing with reliability, availability, maintainability and performance issues. 0trategic investments in the maintenance function can lead to improved performance of manufacturing system and enhance the competitive mar!et position of the organization. This has provided the impetus to the leading organizations worldwide to adopt effective and efficient maintenance strategies. 2. LITER TURE RE!IE" The literature has revealed that the manufacturing organizations worldwide are facing many challenges to achieve successful operation in today's competitive environment. Modern manufacturing requires that to be successful, organizations must be supported by both effective and efficient maintenance practices and procedures. 1ver the past two decades,

manufacturing organizations have used different approaches to improve maintenance effectiveness. Maintenance has traditionally been considered as a support, non-productive and non-value adding function of business. Maintenance has become more challenging in the current dynamic business environment.Maintenance function has typically being regarded as a necessary evil and an operating e"pense to be minimized and not treated as an investment in increasing process reliabity. 2upta et al. 3)**+4 studied the contemporary maintenance management in terms of process, framewor! and supporting pillars. This paper presents a holistic framewor! for managing the maintenance function which begins with reviewing the concept, state of art processes and standards available to help maintain today's comple" systems. Mas%u!i et al. 3)**-4 presented a generic model on using the total productive maintenance concept in con%uction with ecology oriented manufacturing focusing on their %oint strenghts in attaining organizational goals in furtherance to the equipment maintenance ob%ectives. 5hamba et al. 3)**.4 %ustified the total productive maintenance initiatives in Indian manufacturing industry for achieving core competitiveness. The paper aimed at understanding contribution of total productive maintenance initiatives towards building core competencies in Indian manufacturing industry. aa!so et al. 3)**.4 described the value driven maintenance planning for a production plant. In this paper maintenance planning approach is presented !nown as 67M8 to emphasize the fact that the ob%ectives of the plant are the reference points for specifying functional requirements for the equipment locations and the equipments. 0achdeva et al. 3)**94 studied the planning and optimization of the maintenance of the paper production systems in a paper plant. The main ob%ective of this paper was to minimize the total cost of inspection and repair, and equipment downtime. $ditya et al. 3)**:4 discussed the maintenance performance indicators. The purpose of this paper was to present case studies dealing with the application of benchmar!ing and maintenance performance indicators for the railway infrastructure. Maintenance performance indicators can successfully use benchmar!ing as tool for improvement by learning from within or from other organizations for continuous improvement. In this paper, the authors have identified the e"isting maintenance performance indicators used for the railway infrastructure in through two case studies. ,urther research should focus on identifying the

parameters essential for developing lead indicators and on finding methods for selecting and evaluating them, in order to facilitate the outsourcing of railway assets maintenance. 5odali 3)**:4 %ustified the world class maintenance systems using analytic hierarchy constant sum method. This paper aimed to conduct a detailed study in order to understand the shortcomings and see!s to propose various solutions in form of best practices which leads to the development of world class maintenance systems 5umar et al. 3)**:4 studied the implementation of total productive maintenance in large and medium size organizations. The author aims to identify why such programs were introduced, the activities involved, and the effectiveness and difficulties encountered during the process. ;amayah et al. 3)*(*4 studied the total productive maintenance approach. The findings showed that T8M strategies and autonomous maintenance were the highest scoring practices in the study. It is found out that T8M focuses on improving equipment effectiveness, productivity, wor!place safety and environmental issues, and eliminating production losses. This study has investigated the e"tent of T8M practices in manufacturing companies. The findings show that the e"tent of T8M practices in manufacturing companies has good prospects, as all of companies agreed that all the practices are at high levels. 8ophaley et al. 3)*(*4 studied the plant maintenance management practices in automobiles industries in India. The one of the ob%ective of this paper was to investigate the present state of plant maintenance management practices, based on studies conducted in different %ournals over the past two decades. The paper reviews the research wor! on plant maintenance management practices in automobile industries under the traditional operation paradigm. The current wor! gives a broader view of maintenance practices and researches carried across the globe, but as maintenance is now a widely accepted philosophy for competitive advantage, more research wor! is required in auto industries. ,inally, the research needs for future was presented. It is the authors' intention to utilize the !nowledge gained from this literature review to develop a comprehensive and holistic design for maintenance methodology that will be presented in the ne"t part of this research. <a!%ira et al. 3)*()4 did a case study on total productive maintenance in manufacturing industry. The purpose of this paper was to evaluate the contributions of total productive maintenance initiatives towards improving manufacturing performance. The purpose of this paper is to evaluate the contributions of total productive maintenance 3T8M4 initiatives towards improving manufacturing performance in malt manufacturing industry.

0ingh and $hu%a 3)*()4 studied the empirical research evaluates the combined T=M> T8M strategic factors to determine the critical success factors in environmental uncertainty using analytical hierarchy process. 0ingh and $hu%a 3)*(/4 made an attempt to show the synergistic suitability of transfusion of T=M-T8M for Indian manufacturing industries. ,or the study, the most relevant factors affecting these drives li!e quality, cost and maintenance has been considered and further these factors has been simulated by the data given by e"perts in this fields using fuzzy logic toolbo" of M$T $? which provides the steps for designing fuzzy inference systems using graphical tools, and a 0imulin! bloc! for analysing, designing, and simulating systems based on fuzzy logic. 0ingh and $hu%a 3)*()4 reviewed the literature on T=M and T8M and also to study on various T8M and T=M implementation issues in order to develop an indigenous strategic synergetic effect, considering two !ey aspects of profitability and operating performance approach for the manufacturing industry. 5at!amwar et al. 3)*(/4 represented the study and overview for the implementing approach of total productive maintenance in Indian spinning industries. The aim of this paper was to suggest and study the implementation of the T8M program in the spinning industry. This paper presents the study and overview for the implementing approach of Total 8roductive Maintenance in Indian spinning industries. 2.1 T#pes of $arious maintenance practices %eing use& in In&ian 'anufacturing In&ustries 1. (rea)&own maintenance* In this type of maintenance, no care is ta!en for the machine, until equipment fails. ;epair is then underta!en. This type of maintenance could be used when the equipment failure does not significantly affect the operation or production or generate any significant loss other than repair cost. However, an important aspect is that the failure of a component from a big machine may be in%urious to the operator. Hence brea!down maintenance should be avoided. This maintenance strategy was primarily adopted in the manufacturing organizations, worldwide, prior to (:-*. In this phase, machines are serviced only when repair is drastically required. This concept has the disadvantage of unplanned stoppages, e"cessive damage, spare parts problems, high repair costs, e"cessive waiting and maintenance time and high trouble shooting problems.

2. +re$enti$e maintenance* This concept was introduced in (:-(, which is a !ind of physical chec!-up of the equipment to prevent equipment brea!down and prolong equipment service life. It is a daily maintenance 3cleaning, inspection, oiling and re-tightening4, design to retain the healthy condition of equipment and prevent failure through the prevention of deterioration, periodic inspection or equipment condition diagnosis, to measure deterioration. It is further divided into periodic maintenance and predictive maintenance. @ust li!e human life is e"tended by preventive medicine, the equipment service life can be prolonged by doing preventive maintenance 8M comprises of maintenance activities that are underta!en after a specified period of time or amount of machine use. The preventive wor! underta!en may include equipment lubrication, cleaning, parts replacement, tightening, and ad%ustment. The production equipment may also be inspected for signs of deterioration during preventive maintenance wor!. ,. +re&icti$e maintenance* 8redictive maintenance is often referred to as condition based maintenance 3A?M4.This is a method in which the service life of important part is predicted based on inspection or diagnosis, in order to use the parts to the limit of their service life. Aompared to periodic maintenance, predictive maintenance is condition-based maintenance. It manages trend values, by measuring and analyzing data about deterioration and employs a surveillance system, designed to monitor conditions through an on-line system. #.g. ;eplacement of coolant or oil, if there is a change in colour. Ahange in colour indicates the deteriorating condition of the oil. -. Correcti$e maintenance* It improves equipment and its components so that preventive maintenance can be carried out reliably. #quipment with design wea!ness must be redesigned to improve reliability or improving maintainability. This is a system, introduced in (:-., in which theconcept to prevent equipment failures is further e"panded to be applied to the improvement of equipment so that the equipment failure can be eliminated and the equipment can be easily maintained 3improving equipment maintainability4. The primary difference between corrective and preventive maintenance is that a problem must e"ist before corrective actions are ta!en. The purpose of corrective maintenance is improving equipment reliability, maintainability, and safetyB design wea!nesses 3material, shapes4B e"isting equipment

undergoes structural reformB to reduce deterioration and failures, andto aim at maintenancefree equipment. .. 'aintenance pre$ention* Introduced in (:C*s, this is an activity wherein theequipment is designed such that they are maintenance free and an ultimate idealcondition of Dwhat the equipment and the line must beE is achieved. It indicates the design of new equipment. <ea!ness of current machines is sufficiently studied 3on site information leading to failure prevention, easier maintenance and prevents of defects, safety and ease of manufacturing4. The observations and the study made are shared with the equipment manufacturer and necessary changes are made in the design of new machine. /. +ro&ucti$e maintenance 0+'1* 8roductive maintenance means the most economic maintenance that raises equipment productivity. The purpose of productive maintenance is to increase the productivity of an enterprise by reducing the total cost of the equipment over the entire life from design, fabrication, operation and maintenance, and the losses caused by equipment degradation. The !ey characteristics of this maintenance philosophy are equipment reliability and maintainability focus, as well as cost conscious of maintenance activities. The maintenance strategy involving all those activities to improve equipment productivity by performing 8reventive Maintenance, Aorrective Maintenance and Maintenance 8revention throughout the life cycle of equipment is called 8roductive Maintenance. ,. NEED 2OR +RE3ENT 3TUD4 There is abundant literature on the maintenance practices from different perspectives, including their role in improving the competitive positions of nations and economic zones. $fter successful institutionalization of maintenance programs in the organizations, concerted efforts must be made to ensure sustained maintenance deployment in the manufacturing organizations, as manufacturing improvements are only possible through persistent deployment of maintenance initiatives. $ccording to the literature review it has been found that various maintenance practice are implemented in various large scale industries for obtaining various business performance outputs in manufacturing industries. 0o, a need is felt to study the implementation rate of these maintenance practices in the small and medium scale Indian industries. $s these maintenance practices will help in contributing in the improvement of their business performances measures. .

-. O(5ECTI!E3 O2 3TUD4. $s the Maintenance practices being much in vogue in Indian manufacturing industries, a need is felt to e"amine the efficiency of these maintenance practices in the small and medium scale industries in the northern region of the country. $n investigation into this issue will help answering some vital questions on implementation of these practices in manufacturing industries in Indian conte"t. The ob%ectives of this study are to find out the prevailing situation of these maintenance practices in small and medium scale industries and also to e"amine the effectiveness of maintenance practices to improve business performance measures of Indian manufacturing organizations .. 3CO+E O2 3TUD4. The study shall be carried out in the small and medium scale manufacturing organizations in the country that have implemented or are in the process of implementing various maintenance practices. The study will focus on the e"tent up to which the different maintenance practices are being practiced at the industries in the northern region of the country. $lso the study will involve the evaluation of the contribution of the maintenance practices in improving the business performances of the industries. /. I33UE3 TO (E E6+LORED IN T7E 3TUD4. The following issues shall be ta!en up during the research wor!F (. The prevailing status of various maintenance practices used in small and medium scale industries in the northern region of the country. ). #valuating the contribution of various maintenance practices in improving the business performance. 8. 'ET7ODOLO94 +RO+O3ED. (. The detailed literature review shall be carried out to ascertain the contributions of maintenance practices towards improving the business performances for meeting the global competition. ). 0urvey of various manufacturing units shall be carried out through a specially designed questionnaire for understanding and assessing the prevailing situation. /. The research will be based on empirical data collected through a questionnaire from Indian companies. The industries for study will be selected from northern locations to obtain findings for manufacturing industry.

+. The questionnaire will clearly see! information from the respondents to indicate the types of maintenance practices adopted by the company. It will also require the respondents to rate the improvements contributed by the selected practice over the period of implementation. -. The information obtained through the questionnaire shall be analyzed to ascertain the contributions of maintenance practices towards achieving manufacturing competencies of the Indian Manufacturing Industry.

:. C7 +TER +L N. C7 +TER ; 1* Intro&uction In this chapter, the significance of maintenance function towards improving the manufacturing performance shall be discussed. Moreover, the contributions of maintenance practices towards manufacturing performance enhancements for meeting global competition will be elaborated. C7 +TER ; 2* Literature Re$iew The detailed literature on maintenance practices and its development shall be analyzed and the e"periences of the northern side of Indian entrepreneurs shall be elaborated. C7 +TER ; ,* Design of the 3tu&# The design of the study shall emphasize on the methodology adopted for analyzing and synthesizing the collected information through the questionnaire. C7 +TER ; -* nal#sis of the Data The information obtained through the questionnaire shall be analyzed to ascertain the contributions of maintenance philosophies towards manufacturing competencies of the Indian Manufacturing Industry. C7 +TER ; .* Conclusions< Limitations an& scope for future wor) The conclusions derived from the synthesis of the data in a sequential manner shall be presented, limitations of the study shall be highlighted and scope for the future wor! shall also be suggested.

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