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INFORMATION SHEET

Sl.no 1. 2.

Topic Introduction Types of Maintenance

Page no. 3 6

3. 4.

Breakdown Maintenance Preventive Maintenance

9 11

5. 6.

Preventive Maintenance Of Plant and Machinery Classification of Machines With Respect to the Criticality

13 16

7.

Maintenance by the Operator

17

8.

Preventive Maintenance Under Millwright Organization

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9. 10.

Categorization of Equipment Inspection

21 23

11. 12.

Lubrication Storage and Handling of Lubricants

27 30

9.

Maintenance Records

31

10.

Maintenance Planning

34

11.

Spares and Maintenance Materials

36

12.

Economic Order Quality

Measuring Instruments Used for Geometric Testing of Machine Tools

37

13.

38

17. 18.

Total Productive Maintenance Maximizing Equipment Effectiveness

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INTRODUCTION
Efficient use of plant and equipment is a vital factor for industrial growth, particularly in a developing economy like ours. Plant and equipments besides being very expensive, are in many cases imported involving important foreign exchange. Further the cost of plant and equipment forms a considerable portion of the total cost of production. Thus it is imperative to look after them as it provides a means to maintain the plant and equipment in a high state of operating efficiency and enhance its productivity. Poor maintenance causes economic losses such as: a) Increased downtime b) Poor efficiency c) Deterioration of equipment d) Poor quality of product e) Higher labor costs f) Loss of material in process g) Higher production costs h) Increased hazards etc,.

Systematic maintenance procedure offers tremendous possibilities for saving money, material, man power and time. These savings come through: a) Reduction in down time b) Reduced losses of material in process c) Increased life of equipment d) Reduction in over time e) Optimum spares inventory f) Timely replacement of spares and machines g) Maintenance of product quality h) Proper running of the equipment i) Optimum operational cost of the machines Through proper maintenance the down time of equipment comes down considerably. Machines are attended before they break down. Spare parts are replaced before they fail. Lubrication is done regularly and according to a time table. All these and many other activities keep the equipment in good running condition.

Why is maintenance required? Machines buildings and other service facilities are subjected to deterioration due to their use and exposure to environmental conditions. Deterioration of machine implies change in dimension of its various components and weakening of its members due to fatigue, impact and corrosion. With the advancement of technology and growth of industries, the obvious attention has been bestowed to achieve economy by all possible means in order to bring down the production cost. This has brought up the cautious and scientific way of tackling maintenance problems. Objective of maintenance: The objective of maintenance is to provide a condition of machines and services that permits to an uninterrupted implementation of plans involving their use at a cost that optimizes returns on money invested in men, materials and machines.

Types of maintenance:
(a) Capital replacement (b) Provision of Standby capacity (c) Breakdown maintenance (d) Scheduled maintenance (e) Planned maintenance (f) Preventive maintenance (g) Systematic maintenance

(a) Capital replacement: A replacement is affected when: (a) An equipment ages to an extent that the cost of maintaining it in the required condition provides gains that are less than those reliable from investment in a new unit. (b) A better machine emerges in the market rendering the original unit obsoletes.

(b) Provision of Standby capacity: (a) A standby ties up capital. It is often provided for such equipments that are critical to production.

(c) Breakdown maintenance: It leads to disruption of production plans. It also makes it possible to plan the work-load and the distribution of maintenance work force for a balanced attention of all equipments. It increases overtime payment and prolongs down time.

(d) Scheduled maintenance: This system provides for inspection overhaul, lubrication and servicing of certain machines, at predetermined date. It is practiced, in those companies where break down maintenance is otherwise a rule. Mere scheduling is not sufficient. It cannot ensure completion of work in time as the work load remains unknown.

(e) Planned maintenance: It is an advancement over the above maintenance practices. Planned maintenance visualizes the work contained in a nature job. It determines the best method to be adopted, estimates the time, material and cost involved, assigns jobs to individuals etc. It provides a system of feedback of information for necessary changes in the original plan.

(f) Preventive maintenance: It consists of routine actions taken in a planned manner to prevent break down and to ensure operational accuracy to the extent it is economically and practically possible to do so. Lubrication and inspection are the two wings of preventive maintenance. Lubrication ensures long life, inspection tries to detect faults and correct them.

(h) Systematic maintenance: It is the judicious admixtures of the stated practices in maintenance management.

Maintenance practices can be broadly classified into the following two types: A) Breakdown maintenance B) Preventive maintenance

Breakdown Maintenance:
In case of break down maintenance the equipment is generally attended only when it comes to breakdown. The maintenance crew will carry out the necessary repairs, when the machine has actually broken down and is not able to function, in order to put it back into commission. Such break downs may occur to any machine at any time. There are many disadvantages in this system. Some of them are a) There is always an urgency to put the machine back in the working condition and hence the machine may not get adequate maintenance. b) Since the type and time of break down is uncertain, production plans get completely disturbed. c) Planning of maintenance work is not possible. d) Distribution of work load is difficult. e) Results in imbalanced utilization of maintenance staff.

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f) May result in over or low staffing of maintenance department. g) Increased overtime. h) Increased downtime of equipment due to non availability of man power. i) Excessive inventory of spares. j) Waste of materials in process. k) Poor working conditions of maintenance staff. However, breakdown maintenance system may be suitable in certain conditions such as: a) Where plant capacity exceeds market demand. b) Standbys are available and quick switching over is possible. c) Process is obsolete and more modern equipment is under consideration. d) May be economical for non critical equipment where this type of maintenance is cheaper than any other system.

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Preventive Maintenance:
As the name itself indicates preventive maintenance is based on the old age sayings prevention is better than cure and a stitch in time saves nine. Preventive maintenance is a systematic maintenance procedure where in the condition of the plant is constantly watched through a systematic inspection and preventive action taken to reduce the incidence of breakdowns. The necessity of either major or minor repairs is determined to prevent unscheduled interruptions to the plant and equipment or any deterioration The fundamental activities of preventive maintenance are: a) Periodic inspection of plant and equipment. b) Up-keep of equipment to remove or repair of such conditions while they are still in a minor stage. Thus the essence of the preventive maintenance is a well planned inspection system. Proper inspection at the right time is the crux of the preventive maintenance system. Recording of facts revealed during such inspections is another important point. Analyses of such records indicate the type of maintenance work needed, replacements required, planning of maintenance work and inventory of spares. Preventive maintenance renders .

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more effective use of manpower and materials and helps to attain greater efficiency in plant operation. It is possible to synchronize the maintenance program so that there is at least interruption to continuous operation and production. The various elements of a preventive maintenance system in an industry are as follows: a) An inventory of all plant and equipment that need to be maintained. b) Categorization of equipments to assess the relative importance and there by determine the equipments requiring preventive maintenance. c) A well designed inspection system. d) A good lubrication system. e) Maintenance of adequate records and analysis of the records. f) Planning of maintenance work. g) Control of maintenance stores and spares. h) Organization of preventive maintenance work.

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Preventive Maintenance of Plant and Machinery Preventive Maintenance:

Preventive maintenance calls for taking an equipment for repair at planned intervals, so that uncalled for break-down can be prevented. These intervals are decided mainly keeping in view the complexity of the equipment and its load conditions. The position of the equipment is equally an important consideration as to whether the equipment has got its individual function or else it forms a part of a production sequence with other equipment. Where as on one hand, the preventive maintenance helps, in prolonging the life of the equipment ( of the order 3-4 times) and reduction in unexpected breakdowns, on the other hand it ensures the accuracy of the equipment thus maintaining the quality and continuity of production.

Program of Preventive Maintenance:

1. Lubrication 2. Cleaning 3. Adjustments 4. Application on protective coatings

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5. Inspection of the state of components 6. Analysis of history of behavior of the machine and its components 7. Replacement of worn out components 8. Repair of working components 9. Repair of cracks and other repairable damages 10.Modification of design of the components or location of the equipment 11.Capital replacement The first four steps are taken to reduce friction, wear and effects of environment on the individual parts of the machine. For example, lubrication reduces friction, cleaning prevents corrosion and abrasion due to rust, adjustments of level or alignments or by tightening the loose bolts and nuts eliminate undue stresses. These actions increase the useful life of the parts and, therefore constitute an intrinsic part of preventive maintenance. Inspection of parts and analysis of history are meant to assess the condition of the parts, the extent of wear, the action required to remedy the defect and the time when such action should be undertaken. Analysis of such record helps eliminate the life span of various components, and establish the frequency of inspections, repairs and replacements.

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Modification of design of the components or location of the equipment to avoid recurrence of trouble is undertaken on the basis of history of the equipment and evaluation of costs involved. As the age of the machine increases the cost of maintenance rises and operational efficiency of machines comes down. Requirements of quality and quantity of production make an old machine more or less osculate in relationship to the new demands. Due to the advancement of technology new and better machine emerge in the market. Often these factors make it necessary to replace existing machines at some stage in their life with new machines. The degree of maintenance effort and attention required for a machine is dependent on the importance of the machine. The importance of a machine can be assessed in terms of costs, effect on companys reputation and the safety of the employees. Based on the above condition each machine should be placed in one of the following three categories.

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Classification of the machines with respect to the criticality of the machines:

Critical Machines: These machines require rigid operating instructions, inspection schedules and procedures, cleaning schedules and controlled lubrication. Most of the effort of preventive maintenance department should be on these machines and down time should be strictly controlled. Semi-Critical Machines: These machines require moderate operating instructions, inspections, cleaning and lubrication schedules. Break downs should be reduced. Non-Critical Machines: These machines require less operating instructions, inspection, cleaning and lubrication schedules. These machines can be attended after break down. Preventive maintenance schemes can be broadly divided into: 1) Maintenance by the operator and 2) Maintenance by preventive maintenance group under Millwright organization.

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Maintenance by the operator:

The operator is required to attend to the following: (a) Daily cleaning of the machine bed, sideways, lubrication points and working surfaces. He must check up oil level, start and see oil flow daily before starting work. (b) All lubrication points which have to be lubricated by the machine operator may be painted with a distinctive for grease lubrication. Such lubrication points which are mot to be touched by the operator are marked with cross. (c) The operator should follow the instructions given in the maintenance manual for each machine. The maintenance manual and instruction book should be made available on the shop floor. (d) The operator should immediately report to the concerned person or the maintenance personnel if there is anything wrong with the machine.

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Preventive Maintenance Under Millwright Organization:

For this purpose the preventive maintenance scheme may be organized in the following categories: (a) Daily Schedule (b) Weekly Schedule (c) Monthly Schedule (d) Quarterly Schedule (e) Half Yearly Schedule (f) Annual Schedule The broad outline of the nature of the maintenance work to be done on the various types of tools following the above is given below: (a) Daily Schedule: 1. Clean, oil and grease bearings and slides. 2. Check all bolts and nuts. 3. Check and lubricate the main/counter shaft bearings. 4. Check safety devices and overload preventive devices, limit, switches, brakes, etc.

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(b) Weekly Schedule: 1. Check up oil level and top up. 2. Check up coolant. 3. Check and adjust gland packing where ever necessary. 4. Check up relay contractors for motor magnetic clutches. (c) Monthly Schedule: 1. Check pump and fittings. 2. Clean filter oil strainers felt wipers, cover oil pump and taking up slacken wedges and liners. 3. Check and adjust main clutch, clutch pins and clutch blocks. 4. Check and adjust self action of slides and turret. 5. Check up tension and adjust belt. 6. Grease all points wherever indicated. 7. Check and refill coolant tank if necessary. 8. Check lubricating system and pipes for blocks. (d) Quarterly Schedule: 1. Clean and check bearings of head stock. 2. Check up tool post and turrets.

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(e) Half Yearly schedule: (A) Lubrication: 1. Over haul of lubricating system. 2. Clean, flush and refill of lubrication points. 3. Clean, flush and refill feed drive unit. (B) Inspection: 1. Check up the gear shaft clutches and brakes 2. Bearing drive gears 3. Lead screw 4. Shaft bearing 5. Tool posts 6. Turret side locks 7. Lubricating and coolant pumps 8. Pipes and pipe connections 9. Tail stock 10.Slide and slide beds etc. (f) Annual schedule: 1. Alignment test 2. Joint inspection for speed, feed, load test, electrical drive and gear. 3. Overhaul electric motors. 4. Annual repairs limited to overhaul of machine.

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Categorization of Equipments
Before embarking on an elaborate preventive maintenance program, the management will have to make a careful analysis as to which type of equipment need preventive maintenance. It may not be economical to have preventive maintenance for each sundry machine. Factors to be taken into consideration for categorization of equipments: a) Whether the equipment is continuous or intermittent running equipment. An unscheduled or a sudden break down of a continuous running machine with a high degree of utilization will obviously cause considerable production loss. b) In the event of failure of a particular machine, whether a substitute or a standby machine is available. If there is a standby the same can be lastly switched on without any delay and mean while the machine can be repaired and put in condition. c) How important is the machine from the point of view of the quality of the produce that is coming out of the machine. In other words what could be the loss as a result of poor quality of rejections. d) What is the position with regard to availability of spares, easy or difficult to obtain.

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e) What are the likely hazards that the equipments can cause on the workers and other employees. Equipments which have certain hazards need miraculous care. Questions such as above and similar are to be answered for each piece of equipment and an evaluation chart is done jointly by the production and maintenance personnel in order to arrive at the overall criticality. Machines of similar degree of importance can be grouped together which in turn will help to determine the type of analysis priority of preventive maintenance can be decided.

Inspection

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Inspection is the crux of preventive maintenance inspection programs. Inspection of the equipment is carried out in a systematic way periodically in order to determine the condition of equipment. Certain parts may wear out or deteriorate, certain bolts and nuts may become loose due to vibrations, certain surfaces may get eroded, defects may occur as a result of overheating, alignment may go out of order and host of defects may develop in an equipment. These defects if not corrected may result in malfunctioning or breakdown of the machine or cause hazards. Correct action can be taken in time and breakdown or hazards can be avoided. In other words, through a process of inspection it will be possible to check the condition and take preventive measures, which may include repair, reconditioning or replacement of defective parts. Hence, inspection is very important aspect of preventive maintenance. Methods of Inspection: There are different methods by which the equipments can be inspected. They can be broadly classified into a) External inspection b) Internal inspection

What to Inspect?

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Each equipment will have a number of assemblies, sub assemblies and components. Every item in an equipment will have its own design characteristics, and its own functions to perform. Certain defects are also bond to develop based on various factors such as nature and conditions of operation, age, quality and quantity of materials processed etc. If these defects are not corrected in time they may lead to failures and breakdown. Based on experience and judgment and through detailed study equipment a maintenance engineer would be able to list out all the items in an equipment which need to be inspected.

Inspection Frequency:
When once the items to be checked have been listed out in detail, the next logical question is to decide when or how often it is to be inspected. While every item needs to be inspected, but all of them need not be inspected at same interval or frequency. The importance and criticality varies. Every inspection is associated with a cost. Too frequent an inspection will increase the cost inspection, besides involving more

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downtime if inspection is to be carried out during shut down, while under inspection may result in frequent breakdowns.

Use of checklists:
In order to ensure correct and proper inspection check lists are of great importance. Check list is a guide indicating the items to be inspected in each equipment. The list may include what is to be checked, how is it to be checked, when is it to be checked and the standards of acceptance conditions. Preparation of check lists requires considerable skill, experience and judgment. Carefully prepared exhaustive check lists would be of immense help to an inspector and ensure that no item or defect is overlooked and the inspection is carried out properly.

Who should inspect:

An inspector should be an experienced person or a skilled worker with full knowledge of the machines he is inspecting. He should be able to detect unhealthy sign in any equipment and interpret the condition. The level of

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the inspector would depend on the types of process, nature of equipment etc.; an inspector could be a skilled mechanic or an engineer depending on the level of sophistication.

Lubrication

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Lubrication is an important activity in any system of maintenance. The functions of a lubricant are: a) To reduce friction and wear and tear between the moving parts. b) To economise power consumption. c) To keep the bearings with in allowable temperature limits. d) To protect them from dust and erosion etc., Correct lubrication of all moving parts is necessary to ensure proper running of the equipment. To maintain plant efficiency and to prolong the life of the equipments and its components. A well conceived lubrication program should include selection correct lubricant, its application by the right method at proper frequency. Storage, handling, identification and standardization of lubricants are also to be covered in the program. Lubricants are sold under different types of brand names. However, they can be broadly classified into: a) Spindle oils. b) Electric motor oils. c) Gear oils. d) General bearing oils. e) Turbine oils.

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f) Air compressor oils. g) Refrigeration compressor oils. h) Steam cylinder oils. i) Automotive oils. j) Cutting oils. k) Hydraulic oils and l) Greases.

Lubrication oils are selected on the basis of physical properties required for operating conditions. Some of the major characteristics of lubricating oils are: a) Viscosity. b) Flash point. c) Fire point. d) Pour point. e) Carbon residue content. f) Emulsification.

Lubricating methods:

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Lubricating methods have an influence on the efficiency of the lubrication and the selection of lubricant. The methods of applying lubricating oils to moving parts may be classified into four groups. They are: a) Once through oiling. b) Oil reservoir. c) Circulating oil system. d) Other oiling devices.

Storage and handling of lubricants:

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Use of lubricants which are contained with dirt or other foreign materials can cause great damage to costly machinery. Utmost care is therefore, necessary to be exercised in the storage and handling of lubricants. They should be stored in a clean and dry place under cover to prevent deterioration and contamination due to exposure to varying environment. Handling and storage of lubricants goes a long way in proving the efficiency of the lubrication. Color and symbol codes are used to indicate the type of lubricant used and the frequency of application. A particular color will indicate the type of lubricant and a specific symbol such as triangle, circle, rectangle etc., will indicate the frequency of use. Right from the containers in store including the handling and dispensing equipment to the points of application will have same color code. The application points can have the symbol in addition. Alternatively a diagram on the machine with color and symbol codes will indicate the points. Such a system of coding will ensure the use of right lubricant, at the right time for the right time for the right point even by an illiterate worker.

Maintenance Records:

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Building up of the data and an analysis of the same is one of the basic aspects of preventive maintenance. Some data is normally maintained in the form of log books by every maintenance department. But this is mostly incomplete and haphazard and would not serve and would not serve any useful purpose if any analysis is to be carried out. Various decisions involved in respect of inspection to carried, repairs and replacements to be undertaken, manpower to be provided, spares to be stocked and schedules to be drawn up, are all dependent on an analysis of accurate data. Installation of a preventive maintenance system and refinement of the system for effective results calls for a proper data bank, while proper work is essential, it should be reduced to the minimum.

(A) Instruction, Manuals and Drawings: Machinery manufacturers supply the manuals along with the equipment. These manuals contain some very useful information regarding the operation and maintenance of the equipment. They are very valuable guides for installation, commissioning and running if the equipment. (B) Equipment Data:

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All relevant information about each and every equipment should be available in the maintenance department. Equipment data sheet will contain the data like: (a) Description of the equipment. (b) Suppliers name. (c) Data of installation. (d) Cost of equipment. (e) Physical dimensions. (f) Operating characteristics. (g) Spare parts required. (h) Type of lubrication required etc.

(C) Equipment History Card: This is the record of all the repairs, overhauls, modifications and replacements done on equipment. All the events that have occurred during the life span of equipment systematically recorded, giving complete history of the equipment. The history cards enable the maintenance man to study the behavior of the equipment and analyze the life of parts, spares and refine inspection plans and decide modifications.

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The data thus collected through history cards will have to be further analyzed in detail in order to determine the cause of failures and decide on the corrective action to be taken. The possible causes for failure may be further classified as: (a) Defective design. (b) Defective material. (c) Poor maintenance. (d) Improper operation. (e) Environment and working conditions etc.

Maintenance Planning

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Planning of maintenance work involves deciding as to what jobs are to be done, how they are to be carried out, when they should be taken up and the various resources required to do the work. The objective of planning is to carry out all the jobs in the most effective way using the correct amount of resources. Maintenance planning will consist of: (a) Forecasting future work. (b) Determine the best method of carrying out the work. (c) Arranging for the spares and other maintenance materials required. (d) Working out a scheduled in consultation with the production departments. (e) Deciding the number and type of people required to do the job. (f) Allocation of the work to individuals. (g) Follow up and control regarding progress of work.

Scheduling:

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Scheduling is the preparation of a time table, showing the allocation of the various jobs to specific time periods. In order to prepare such a schedule the estimate of time required for various jobs is necessary. The jobs to be done are all collected and the total man hours required is estimated. Once the man hours required are computed craft wise, it is compared with the available man hours. The jobs are then scheduled according to the priority and the availability of the man hours. Scheduling of maintenance work requires detailing of maintenance and production schedules. Hence, it is necessary to involve production personnel in decision making regarding jobs to be carried out, priority of each job and the time when it is to be under taken. It may be advisable to prepare a schedule for a period of 2-4 weeks and finalize it in consultation with production. Schedules can be prepared in two stages, long term and short term schedule will be a final and a detailed breakup of work for the next one week. The authorization for executing the work will be through a work order which will give the details of work to be done. Materials required for the work will be drawn against authorized materials requisitions. Time spend on each job/work order will be booked in the time cards by the foreman on the individual employees.

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Spares and Maintenance Materials

A proper control of spares and stores in an essential feature of any maintenance plan. Planning and scheduling of maintenance work to be effective, the spare parts should be made available as and when required. At the same time, over stocking of materials results in. (1) un-necessary blocking of valuable capital. (2) wastage of storage space. (3) deterioration and obsolescence materials. Hence, it is necessary to control and regulate the material inventory.

Inventory ControlGeneral concepts :: ABC and VED analysis: The two types of analysis that are suitable for maintenance planning are: (a) ABC analysis and (b) VED analysis (Vital, Essential, Desirable). In the former the emphasis is on inventory value, where as in the latter the basis is criticality of the item.

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Economic Order Quality

When the store items have been classified according to their relative importance the next question would be to determine in what quantities an item is to be ordered each time. Often it is determined on a thumb rule basis. But this is a decision that needs to be taken on the basis of economic consideration. Computation of ordering quality involves two costs (a) ordering costs (b) inventory carrying costs. Placement of a purchase order for any material is associated with certain obvious costs like stationery, postage, telephone bill, telegram and supervisory cost etc., involved in processing the paper and expediting the delivery. As the number of orders goes on increasing, the ordering cost will also increase. Whenever any material is kept in store there are certainly costs incurred such as interest charges such as interest charges, cost of storage space, man power, insurance, deterioration and obsolescence. The inventory carrying out cost will increase as the quality stored at any given time increases.

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Measuring Instruments Used For Geometrical Testing Of Machine Tools:

The following are the basic instruments employed in the geometrical testing of the machine tools: 1) Dial Gauges 2) Test Mandrels 3) Straight Edges 4) Master Cylinder

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Introduction to Total Productive Maintenance:

In todays competitive environment, we cannot settle for less ambitious goals than the total elimination of breakdowns and other losses and continuous production. The concept of Preventive Maintenance was adopted in America early in 1950s Mr. Seilchi Nakajima of Japan began studying American concept of Preventive Maintenance in 1950. He had first visited the United States in 1962. Since then every year he had visited American and European manufacturing industries to study their manufacturing facilities and learn more about their Productive Maintenance System. Based on his observation he developed Total Productive Maintenance (TPM) and introduced it in Japan in 1971. In September 1987 he had led a Maintenance Study Mission to the USA. During the two weeks stay, the team made presentations on TPM at several companies and at the fourth international Maintenance Conference in Cincinali sponsored by the Institute of Industrial Engineers. Subsequently the team organized many conferences on TPM covering about 80 companies. Many other industries were showing obvious enthusiasm to implement TPM in their companies.

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More than 150 industries were awarded for the implementation of TPM program since 1971. Worker productivity increased by 60% and accident break downs were reduced from1/100 to 1/500 nearing zero. Most of the companies of Toyota group adopted TPM and were awarded for its implementation. Then Southeast Asian countries like Thailand, China, Korea, Taiwan etc started implementing TPM in their industries. In 1970 EFNMS (European Federation of National Maintenance Societies) was established in Europe. After that France and Brazil realized the importance and advantages of TPM and implemented it. There was a lot of resistance for autonomous maintenance by operators and labor union in Japan and USA. TPM is quickly becoming an internationally recognized system. In 1998 m/s Sundaram Fasteners got TPM award by Japan Institute o Plant Maintenance.

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Maximizing Equipment Effectiveness:

Measuring Availability: It is the ratio of operating time to loading time

Availability =

operating time Loading time

loading time down time Loading time

In this way the loading time or available time per day or month can be determined. Loading time = total available time per day or month planned down time. Planned downtime = the amount of downtime officially scheduled in the Production Plan. (i.e. downtime for scheduled maintenance and management activities)