BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI

WORK INTEGRATED LEARNING PROGRAMMES

COURSE HANDOUT

Academic Term

SECOND SEMESTER 2014-2015

Course Title

Maintenance and Safety

Course ID No.

ENGG ZC242

Instructor(s)

N SURESH KUMAR REDDY

Course Modules (add more rows as per needs)

Module
No

Module Title

Objectives

Introduction to Maintenance
Systems

Introduces the concept of repair and

maintenance

Maintainability

Explains the concept of maintainability

3-4

Condition-Based Maintenance
(CBM)

The advantages of maintenance

system highlighted

5-6

Reliability Centred Maintenance

(RCM)

Provides an overview of the concept of

reliability

Asset and Spare Parts

Management

Focusses on Asset and Spare Parts

Management

Maintenance Lubricants and Their Provide focus on purpose of lubricants

Applications, Key Definitions in
Lubrication

Review Session

Syllabus for Mid- Semester Test (Closed Book): Topics in S. No. 1 to 9

10-11

Safety Engineering and Fault Tree

Analysis

It gives a brief overview of safety

engineering

12

Total Productive Maintenance

Deals with TPM and OEF

13

Maintenance Planning and

Scheduling

Explains different aspects of planning

and scheduling of maintenance

14

Computer Applications in
Maintenance Management

Enumerates the major advantages of

using CMMS

15

Statistical Distribution in
Preventive Maintenance

Focuses on different types of statistical

distributions

16

Maintenance Integration

Deals with the importance of

integrated approach to carryout they
maintenance function

17

Maintenance Effectiveness

Focusses on topic of maintenance

effectiveness

18

Review Session

Syllabus for Comprehensive Exam (Open Book): All topics given in plan of study
Text Book(s)
T1

T1.

K. Venkataraman, Maintenance
Prentice Hall of India, 2007.

Engineering

and

Management,

Reference Book(s) & other resources

R1

Mishra R.C. & K. Pathak, Maintenance Engineering and Management,

Prentice-Hall of India., 2002

R2

Sushil Kumar Srivastava, Industrial Maintenance Management, S. Chand &

Company, 2002.

R3

Krishnan N.V., Safety Management in Industry, Jaico Publishing House,

1993.

R4

L M Deshmukh, Industrial Safety Management, TMH, 2006.

R5

Maintenance Management: Its Auditing and Benchmarking: In Search of

Maintenance Management Excellence by Anthony Kelly , Industrial Press
2006 (336 pages)

R6

Total Productive Maintenance by Terry Wireman , Industrial Press 2004

(204 pages)

Self-Study & Contact Session Plan

Module Title:

Introduction to Maintenance Systems

Session 1

Topic
No.

Topic Title

Reference

1.1

Maintenance as Business Proposition

T1-Chapter 1

1.2

Maintenance Philosophy

1.3
1.4
Module Title: Maintainability
Session 2

Topic
No.

Topic Title

Reference

2.1

Measure of maintainability,

T1-Chapter 2

2.2

Methods of Evaluation of Maintainability

2.3

Design for Maintainability

2.4
Module Title:

Condition-Based Maintenance (CBM)

Session 3

Topic
No.

Topic Title

Reference

3.1

Improvement effectiveness thru CBM,

T1-Chapter 3

3.2

various CBM techniques,

3.3
3.4
Module Title:

Condition-Based Maintenance (CBM)

Session 4

Topic
No.

Topic Title

Reference

4.1

NDT

T1-Chapter 3

4.2
4.3
4.4
Module Title:

Reliability Centred Maintenance (RCM)

Session 5

Topic
No.

Topic Title

Reference

5.1

Reliability being active and standby,

T1-Chapter 4

5.2

FMECA

5.3
5.4
Module Title:

Reliability Centred Maintenance (RCM)

Session 6

Topic
No.

Topic Title

Reference

6.1

RCFA

T1-Chapter 4

6.2

Criticality analysis

6.3
6.4
Module Title: Asset

and Spare Parts Management

Session 7

Topic
No.

Topic Title

Reference

7.1

Asset management function,

T1-Chapter 5

7.2

EOQ, 2-Bin system of material procurement,

7.3

Mobile computing

7.4
Module Title:

Maintenance Lubricants and Their Applications

Session 8

Topic
No.

Topic Title

Reference

8.1

Maintenance Lubricants

T1-Appendix I

8.2

Lubricant Applications

8.3

Key Definitions in Lubrication

T1-Appendix II

8.4
Session 9: Review Session
Mid-Semester Test (Closed Book) : Topics in Session 1 to 8
Module Title:

Safety Engineering and Fault Tree Analysis

Session 10

Topic
No.

Topic Title

Reference

10.1

Hazard analysis,

T1-Chapter 6

10.2

OSH

10.3
10.4
Module Title:
Session 11

Topic
No.

Topic Title

Reference

11.1

General rules in fire hazard and safety

T1-Chapter 6

11.2

Faulty tree analysis

11.3
11.4
Module Title: Total
Session 12

Productive Maintenance

Topic
No.

Topic Title

Reference

12.1

Methodology

T1-Chapter 7

12.2

Origin, Implementation,

12.3

Lean Maintenance

12.4

Training and monitoring

Module Title:

Maintenance Planning and Scheduling

Session 13

Topic
No.

Topic Title

Reference

13.1

Maintenance planning,

T1-Chapter 8

13.2

Shutdown planning

13.3

Execution

13.4
Module Title:

Computer Applications in Maintenance Management

Session 14

Topic
No.

Topic Title

Reference

14.1

CMMS,

T1-Chapter 9

14.2

Data acquisition

14.3

Software failure

14.4

Software security

Module Title:

Statistical Distribution in Preventive Maintenance

Session 15

Topic
No.

Topic Title

Reference

15.1

Types of distributions

T1-Chapter 10

15.2

Normal distribution

15.3

Gamma distribution

15.4

Binomial distribution etc.

Module Title:

Maintenance Integration

Session 16

Topic
No.

Topic Title

Reference

16.1

Steps of integration,

16.2

future trends

T1-Chapter 11

16.3
16.4
Module Title:

Maintenance Effectiveness

Session 17

Topic
No.

Topic Title

Reference

17.1

Elements of effectiveness

T1-Chapter 12

17.2

Presentation of data

17.3

OEE, Agility etc

Session 18: Review Session

Details of Lab (Online) If any: Evaluation Scheme:
Legend: EC = Evaluation Component; AN = After Noon Session; FN = Fore Noon Session
No

Name

Type

Durati
on

Weigh Day, Date, Session, Time

t

EC-1

Assignment-I/ Quiz-I

Online

15%

February 1-10, 2015

Quiz-II

March 1-10, 2015

Assignment-II/ Quiz-III

April 1-10, 2015

EC-2

Mid-Semester Test

Closed
Book

EC-3

Comprehensive Exam Open

Book

2
hours

35%

22/02/2015 (AN) 2 PM 4 PM

3
hours

50%

19/04/2015 (AN) 2 PM 5PM

Syllabus for Mid-Semester Test (Closed Book): Topics in Session Nos. 1 to 8

Syllabus for Comprehensive Exam (Open Book): All topics (Session Nos. 1 to 18)
Important links and information:
Elearn portal: https://elearn.bits-pilani.ac.in
Students are expected to visit the Elearn portal on a regular basis and stay up to date with the
latest announcements and deadlines.
Contact sessions: Students should attend the online lectures as per the schedule provided on
the Elearn portal.
Evaluation Guidelines:

1. EC-1 consists of either two Assignments or three Quizzes. Students will attempt them
through the course pages on the Elearn portal. Announcements will be made on the
portal, in a timely manner.
2. For Closed Book tests: No books or reference material of any kind will be permitted.
3. For Open Book exams: Use of books and any printed / written reference material (filed
or bound) is permitted. However, loose sheets of paper will not be allowed. Use of
calculators is permitted in all exams. Laptops/Mobiles of any kind are not allowed.
Exchange of any material is not allowed.
4. If a student is unable to appear for the Regular Test/Exam due to genuine exigencies,
the student should follow the procedure to apply for the Make-Up Test/Exam which will
be made available on the Elearn portal. The Make-Up Test/Exam will be conducted only
at selected exam centres on the dates to be announced later.
It shall be the responsibility of the individual student to be regular in maintaining the self study
schedule as given in the course handout, attend the online lectures, and take all the prescribed
evaluation components such as Assignment/Quiz, Mid-Semester Test and Comprehensive Exam
according to the evaluation scheme provided in the handout.