Advanced Maintenance Management: Jose K Puthur RCBS

Advanced Maintenance
Management
Jose K Puthur RCBS
Jose K Puthur
BE Electrical and Electronics (NIT Trichy)
MBA FDP (IIM A)
Worked as Customer Engineer/ Sr Engineer in
HCL Infosystems 4 years
National Informatics centre
Systems Engineer/Sr systems
Engineer/Principal Systems Engineer/Technical
Director/State Informatics officer 20 years
In Rajagiri from 2009
Doing PhD in E-Business/Bharathiar CBE
Definition Maintenance
British Standard Glossary of terms (3811:1993)
defined maintenance as:
The combination of all technical and
administrative actions, including supervision
actions, intended to retain an item in, or restore
it to, a state in which it can perform a required
function.
Definition Maintenance

maintenance is a set of organised activities that are
carried out in order to keep an item in its best
operational condition with minimum cost acquired.

Doctors Day
The Doctor's Day is celebrated on July 1 all across
India to honour the legendary physician and the
Dr Bidhan second Chief Minister of West Bengal,
and died on 1882 , 1 . He was born on July Chandra Roy
the same date in 1962, aged 80 years. Dr Roy was
honoured with the country's highest civilian award,
Bharat Ratna on February 4, 1961.
Raghuram Rajan

Indian Institute of Technology, he graduated from the
, electrical engineering with a bachelor's degree in Delhi
and he completed the Post Graduate Diploma in
Indian Institute of Business Administration at the
. Rajan was a gold 1987 in Management Ahmedabad
medalist in IIT Delhi and IIM Ahmedabad. He received a
Massachusetts Institute from the
] 2 [
PhD in management
1991 (MIT) in of Technology
. Chief Economic Adviser to the Government of India
The rupee fell to a record low on Monday
as an emerging markets selloff after strong
US jobs data laid bare the currency's
vulnerability and dependence on capital
inflows to fund its record current account
deficit.
The rupee was at 61.09, breaching the
previous low of 60.76 hit on June 26.
It had closed at 60.225/235 on Friday.
Bond yields also jumped on fears that
foreign investors would continue to sell
rupee debt.
The 10-year yield rose as much as 13
basis points to 7.63 pct from its previous
close.
Maintenance Activities

Activities of maintenance function could be either
repair or replacement activities, which are necessary
for an item to reach its acceptable productivity
condition and these activities, should be carried out
with a minimum possible cost.
History Maintenance
1. In the period of pre-World War II, people thought
of maintenance as an added cost to the plant which
did not increase the value of finished product.

Therefore, the maintenance at that era was
restricted to fixing the unit when it breaks because
it was the cheapest alternative

History Maintenance
2. During and after World War II at the time when the
advances of engineering and scientific technology
developed, people developed other types of
maintenance, which were much cheaper such as
preventive maintenance.

In addition, people in this era classified
maintenance as a function of the production system.
Breakdown Maintenance or Operate to
Failure or Unplanned Maintenance
Preventive or Scheduled Maintenance
Predictive or Condition Based
Maintenance
Opportunity Maintenance
Motor car
Bike
Air condition unit
Fridge
House
Water supply system
Computer

Road
Electric Motor
Bus
Kitchen
Gas stove
Your hostel room
Lathe
UPS/Inverter
Train
Ship
Air craft
Thermal power plant
Electric Generator
History Maintenance
Fix the equipment
when it breaks
-Term terotechnology
introduced.
-Recognition of need to
present equipment
failures.
-Models for preventive
maintenance
developed.

-Increased awareness
of:
-Environment
-Safety
-Quality
-Need for reliable
equipment.
-Reduction in costs.
Pre-World War II Post-World War II 1980 Onwards

Time
D
e
v
e
l
o
p
m
e
n
t

o
f

M
a
i
n
t
e
n
a
n
c
e

Figure 2.2 Maintenance History
(Adapted From Shenoy, Bhadury 1998)
History Maintenance
3. Nowadays, increased awareness of such issues as
environment safety, quality of product and services
makes maintenance one of the most important
functions that contribute to the success of the
industry.

World-class companies are in
continuous need of a very well organised
maintenance programme to compete world-wide.
Maintenance Objectives
Maintenance objectives should be consistent with and
subordinate to production goals.

The relation between maintenance objectives and
production goals is reflected in the action of keeping
production machines and facilities in the best possible
condition.

Maximising production or increasing facilities
availability at the lowest cost and at the highest
quality and safety standards.
Reducing breakdowns and emergency shutdowns.
Optimising resources utilisation.
Reducing downtime.
Improving spares stock control.
Improving equipment efficiency and reducing scrap
rate.
Minimising energy usage.
Better pollution control
Better safety
Optimising the useful life of equipment.
Providing reliable cost and budgetary control.
Identifying and implementing cost reductions.

PLANT

M
A
I
N
T
E
N
A
N
C
E
Reduce Breakdowns

Reduce Downtime

Improving Equipment
Efficiency
Improving Inventory
Control
Implementing Cost
Reduction
Maximising Production
Optimising Resources
Utilisation
Optimising Useful Life
of Equipment
Minimising Energy
Usage
Providing Budgetary
Control
Figure 2.3 Maintenance Objectives

Integrated maintenance
management system
Department
Production

Material management

Personnel
Area of Interaction
Reliable/availability/
Quality

Effective material
conservation

Optimum utilization of
work force
Maintenance Objective
Result of Poor
maintenance
Increased down time
Poor efficiency
Deterioration of
equipment
Poor quality product
Higher labour costs
Loss of material
Higher production cost
Increased hazards
Benefits of systematic
Maintenance
Reduction in down time
Reduced material
Increased life of the
equipment
Reduction in over time
Optimum inventory of
spare parts
Optimum operational cost
Good product quality
Types of Maintenance
Run to Failure Maintenance (RTF)

Preventive Maintenance (PM)

Corrective Maintenance (CM)

Improvement Maintenance (IM)

Predictive Maintenance (PDM)

The required repair, replacement, or restore action
performed on a machine or a facility after the
occurrence of a failure in order to bring this
machine or facility to at least its minimum
acceptable condition.

It is the oldest type of maintenance.
It is subdivided into two types:
Emergency maintenance: it is carried out as fast
as possible in order to bring a failed machine or
facility to a safe and operationally efficient
condition.
Breakdown maintenance: it is performed after
the occurrence of an advanced considered failure
for which advanced provision has been made in
the form of repair method, spares, materials,
labour and equipment.
Disadvantages:

1. Its activities are expensive in terms of both direct and
indirect cost.

2. Using this type of maintenance, the occurrence of a failure
in a component can cause failures in other components in
the same equipment, which leads to low production
availability.

3. Its activities are very difficult to plan and schedule in
advance.
This type of maintenance is useful in the following
situations:

1. The failure of a component in a system is unpredictable.

2. The cost of performing run to failure maintenance activities
is lower than performing other activities of other types of
maintenance.

3. The equipment failure priority is too low in order to include
the activities of preventing it within the planned
maintenance budget.

It is a set of activities that are performed on plant
equipment, machinery, and systems before the
occurrence of a failure in order to protect them and
to prevent or eliminate any degradation in their
operating conditions.

British Standard 3811:1993 Glossary of terms
defined preventive maintenance as:

the maintenance carried out at predetermined
intervals or according to prescribed criteria and
intended to reduce the probability of failure or the
degradation of the functioning and the effects
limited.

The advantage of applying preventive maintenance
activities is to satisfy most of maintenance
objectives.
The factors that affect the efficiency of this type of maintenance:

1. The need for an adequate number of staff in the maintenance
department in order to perform this type of maintenance.
2. The right choice of production equipment and machinery that is
suitable for the working environment and that can tolerate the
workload of this environment.
3. The required staff qualifications and skills, which can be gained
through training.
4. The support and commitment from executive management to the
PM programme.
5. The proper planning and scheduling of PM programme.
6. The ability to properly apply the PM programme.
It is good for those machines and facilities which
their failure would cause serious production losses.

Its aim is to maintain machines and facilities in
such a condition that breakdowns and emergency
repairs are minimised.

Its activities include replacements, adjustments,
major overhauls, inspections and lubrications.
Researchers subdivided preventive maintenance into
different kinds according to the nature of its activities:

Routine maintenance which includes those maintenance
activities that are repetitive and periodic in nature such as
lubrication, cleaning, and small adjustment.

Running maintenance which includes those maintenance
activities that are carried out while the machine or
equipment is running and they represent those activities that
are performed before the actual preventive maintenance
activities take place.
Opportunity maintenance which is a set of maintenance
activities that are performed on a machine or a facility when
an unplanned opportunity exists during the period of
performing planned maintenance activities to other machines
or facilities.

Window maintenance which is a set of activities that are
carried out when a machine or equipment is not required for
a definite period of time.

Shutdown preventive maintenance, which is a set of
preventive maintenance activities that are carried out when
the production line is in total stoppage situation.
In this type, actions such as repair, replacement, or
restore will be carried out after the occurrence of a
failure in order to eliminate the source of this
failure or reduce the frequency of its occurrence.

In the British Standard 3811:1993 Glossary of terms,
corrective maintenance is defined as:

the maintenance carried out after recognition and intended to
put an item into a state in which it can perform a required
function.
This type of maintenance is subdivided into three
types:

Remedial maintenance, which is a set of activities
that are performed to eliminate the source of failure
without interrupting the continuity of the
production process.

The way to carry out this type of corrective maintenance is
by taking the item to be corrected out of the production line
and replacing it with reconditioned item or transferring its
workload to its redundancy.
Deferred maintenance, which is a set of corrective
maintenance activities that are not immediately
initiated after the occurrence of a failure but are
delayed in such a way that will not affect the
production process.

Shutdown corrective maintenance, which is a set of
corrective maintenance activities that are performed
when the production line is in total stoppage
situation.

The main objectives of corrective maintenance are the
maximisation of the effectiveness of all critical plant
systems, the elimination of breakdowns, the elimination of
unnecessary repair, and the reduction of the deviations from
optimum operating conditions.

The difference between corrective maintenance and
preventive maintenance is that for the corrective
maintenance, the failure should occur before any corrective
action is taken.

Corrective maintenance is different from run to failure
maintenance in that its activities are planned and regularly
taken out to keep plants machines and equipment in
optimum operating condition.
The way to perform corrective maintenance activities is by
conducting four important steps:

1. Fault detection.
2. Fault isolation.
3. Fault elimination.
4. Verification of fault elimination.

In the fault elimination step several actions could be taken
such as adjusting, aligning, calibrating, reworking,
removing, replacing or renovation.
Corrective maintenance has several prerequisites in
order to be carried out effectively:

1. Accurate identification of incipient problems.
2. Effective planning which depends on the skills of the
planners, the availability of well developed maintenance
database about standard time to repair, a complete repair
procedures, and the required labour skills, specific tools,
parts and equipment.
3. Proper repair procedures.
4. Adequate time to repair.
5. Verification of repair.
It aims at reducing or eliminating entirely the need for
maintenance.
This type of maintenance is subdivided into three types as
follows:

1. Design-out maintenance which is a set of activities that
are used to eliminate the cause of maintenance, simplify
maintenance tasks, or raise machine performance from the
maintenance point of view by redesigning those machines
and facilities which are vulnerable to frequent occurrence of
failure and their long term repair or replacement cost is very
expensive.

2. Engineering services which includes construction and
construction modification, removal and installation, and
rearrangement of facilities.

3. Shutdown improvement maintenance, which is a set of
improvement maintenance activities that are performed
while the production line is in a complete stoppage situation.
Predictive maintenance is a set of activities that detect
changes in the physical condition of equipment (signs of
failure) in order to carry out the appropriate maintenance
work for maximising the service life of equipment without
increasing the risk of failure.

It is classified into two kinds according to the methods of
detecting the signs of failure:
Condition-based predictive maintenance
Statistical-based predictive maintenance

Condition-based predictive maintenance depends on
continuous or periodic condition monitoring equipment to
detect the signs of failure.

Statistical-based predictive maintenance depends on
statistical data from the meticulous recording of the
stoppages of the in-plant items and components in order to
develop models for predicting failures.
The drawback of predictive maintenance is that it depends
heavily on information and the correct interpretation of the
information.

Some researchers classified predictive maintenance as a type
of preventive maintenance.

The main difference between preventive maintenance and
predictive maintenance is that predictive maintenance uses
monitoring the condition of machines or equipment to
determine the actual mean time to failure whereas
preventive maintenance depends on industrial average life
statistics.
Types of Maintenance
MAINTENANCE
UNPLANNED
MAINTENANCE
(REACTIVE)
BREAKDOWN

EMERGENCY

PLANNED
MAINTENANCE
(PROACTIVE)
CORRECTIVE
MAINTENANCE
REMEDIAL DEFERRED
PREDECTIVE
MAINTENANCE
CONDITION -
BASED
STATISTICAL
- BASED
PREVENTIVE
MAINTENANCE
ROUTINE RUNNING
DESIGN - OUT ENGINEERING
SERVICES
WINDOW
IMPROVEMENT
MAINTENANCE
SHUTDOWN
CORRECTIVE

SHUTDOWN
PREVENTIVE

SHUTDOWN
IMPROVEMENT
Shutdown Maintenance
OPPORTU-
NITY
Figure 2.4 Maintenance Types

Maintenance Planning
Maintenance planning involves planning
,controlling and recording how ,when and
what jobs are required to be carried out
and resources required to do the jobs in
maintaining the assets in an acceptable
standard
Components of Maintenance
planning
Envisaging the work to be carried out
Determining the best method to do the job
Working out a schedule in consultation
with the production department
Deciding the number and type of
personnel required.
Assessing the time required for the job
Arranging spare parts and materials
necessary for the job and provide
technical information support.
Allocating jobs to individuals
Following up and controlling progress of
work
Maintaining records of jobs, spare parts
used as well as costs incurred
Reasons for Mainenance
Planning
To Protect and ensure a ling life of the
machinary and building by regular and
adequate mainenance
To provide technical and operational
support to the management and personnel
after commissioning
The basic requirement of a
planned maintenance system
1, There should be a register of all assets
2, there should be a schedule for
maintenance work
3,There must be a method of ensuring the
completion of scheduled work ie a control
system
4,There should be a system of recording
and analyzing the performance

Asset Register
1, name of the item
2, Description/specification
3,Reference numbers of the item-
manufacturers suppliers(if any) and users
4, Location of the item- with provision for
changes if the item is interchangeable with
other items
Asset Register
5, Manufacturers /suppliers details
6, Procurement/installation date
7, Initial cost, depreciation etc
8,Axcillary equipment- pumps, motors etc
Special requiremnets for services air
,water,power
Details of items ,which are suitable
substitute

Asset Register
11, availability of operating
instructions/spare parts catalogue
12, Inventory of spare parts against each
machine or piece of equipment
13, Breakdown and repair cost
14, history of the repair/ mantenance
under taken

Overhaul and repair
1. to examine carefully for faults,
necessary repairs, etc.
2. (Engineering / General Engineering) to
make repairs or adjustments to (a car,
machine, etc.)

Overhaul and repair

The Voyager 2 spacecraft is a 722 kg
space probe launched by NASA on August
20, 1977 to study the outer Solar System
and eventually interstellar space. It was
actually launched before Voyager 1, but
Voyager 1 moved faster and eventually
passed it.
Voyager
1
Voyager 1 is a 722-kilogram (1,592 lb)
on NASA launched by space probe
Solar to study the outer 1977 , 5 September
years and 36 . Operating for System
23 days as of September 28, the
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to receive routine Space Network
commands and return data. At a distance
of about 125.75 AU (1.88110
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it is the
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Replacement Decision
In case of a major breakdown of
equipment when the further repair is not
economical or feasible
In the case when the machine becomes
obsolete
In the case of technology upgradation
For cheaper production
Replacement Decision
1, running cost
2, involves large capital expenditure
3, wrong decision may lead to reduction in
profit
Cost factors in the replacement
study
Operating cost
Repair and maintenance
Rebuilding cost
Salvage value

Cost factors not to be
considered
Original cost
Money already spent on repair
Unrealistic book value

For new equipment
Initial cost
Interest on capital
Salvage value at the end of useful life
Cost advantage of improved product
Saving in labour

Methods of replacement studies
Pay back period method
P=c/r
P = pay back period in years
C = original capital invested
r = annual return expected(total annual
earning after deducting taxes )

Present value method

MAPI method
Method has been developed by George
Terborgh the director of the Machinery and
Allied Product Institute Washington
Here the machine which is to be replaced
is called the defender and the new one is
called the challenger
MAPI Chart
In 1949 the Machinery Allied Production
Institute in Washington set up a study
committee chaired by
George Terborgh to come up with a new
evaluation system for investments aimed at
the equipment replacement
problem, which led to a general rule,
usually referred to as the MAPI formula,
that allows
for the determination at a given moment of
the opportuness of replacing an existing
plant with a new
plant that has come on the market, called
the potential challenger plant.
Even if the MAPI formula has been the
focus of criticisms, it offers a general
solution to the equipment replacement
problem that covers a wide range of cases.
Mangalyan: Countdown begins
for Indias first Mars mission
The 56 hours and 30 minutes countdown
started as per schedule at 06.08 AM. It is
proceeding smoothly," a spokesman of the
Indian Space Research Organisation
(ISRO) told PTI over phone this morning.
Once launched, the satellite is expected to
go around the Earth for 20-25 days, before
embarking on a nine-month voyage to the
red planet on December 1 and reach the
orbit of the Mars on September 24, 2014.

Management of spare Parts
To successfully plan and schedule the
maintenance job, the spare parts should
be available at the right time ie as and
when required
Inventory means capital investment
,personnel, storage facilities, movement of
spares
Management of spares
Spares parts should be in stock
Easily identifiable
Should be received immediately on
replacement
The spare parts requirement is irregular
hence forecasting is difficult
Moving parts may fail more compared to
stationary area
SMPS failure rate is high in case of
computers

Company may give more importance to
production targets and the availability of
spares may be a problem
High inventory of spare parts locks up a
sizeable amount of capital owing to
accumulation of slow and non moving
items and obsolete or surplus stock
Management of spare parts
1, wear & tear spares
2, Overhaul spares
3, Insurance spares
Wear &tear spare
These are used to replace parts which are
subject to regular wear & tear and require
to be replaced after a definite number of
hours of operation of the equipment
Overhaul spares
These are used for parts that must be
replaced during overhauling as well as
dismantling and reassembly
Insurance spares
Some parts are generally not subject to
wear & tear during operation of the .
Machinery
How ever their spare parts need to be
stored to safeguard against heavy
downtime cost in case of breakdown
Insurance spares
Spares failure can bring the operations to
grinding halt
Normally they are very reliable
Ex transformer conveyor
Few spares should be kept as spares
Non repairable components
When a component fails it is immediately
replaced the replaced component is not
repaired
OREST Software
Optimal Replacement of Equipment in the
Short Term has been developed
Based on Weibull distribution
Quality,Reliability,Maintainability
& Availability
Quality
Fitness for use
There is nothing like absolute quality
Manufacturer and customer mutually
understand the level of quality
desired function for the required time with
out any failure
Quality
Fitness for use
The user expect to have the product
performance over a specified period of
time under the stated environment
Reliability
Dependable

Trustworthy
Mostly expressed fair, good, excellent
But percentage may be a better way

Means of Controlling Quality
The quality is controlled by controlling
1,Incoming materials
2,Process at the point of production
3,With better maintenance support system
Fig pg 127
Reliability
Is the ability of an item to perform a
required function(without failure)
stated for a conditions stated Under
period of time
Type of Reliability
1,Reliability of design
2,Reliability of manufacture
3,Reliability of use
Factors affecting Equipment
Reliability
At each stage of Design and
Development,Production,Storage and
Transportation and Operation reliability is
affected by the methods used
Fig 128
System reliability
Series, Parallel, mixed configuration
Reliability Theory
Reliability theory describes the
probability of a system completing its
expected function during an interval of
reliability time. It is the basis of
, which is an area of study engineering
focused on optimizing the reliability, or
probability of successful functioning, of
systems, such as airplanes, linear
accelerators, and any other product.
. It statistics and probability ainstream of
Reliability Theory
It developed apart from the mainstream of
. It was originally a statistics and probability
maritime tool to help nineteenth century
companies life insurance and insurance
compute profitable rates to charge their
failure customers. Even today, the terms "
" and "hazard rate" are often used rate
interchangeably
The failure of mechanical devices such as
ships, trains, and cars, is similar in many
ways to the life or death of biological
organisms. Statistical models appropriate
for any of these topics are generically
called "time-to-event" models. Death or
failure is called an "event", and the goal is
to project or forecast the rate of events for
a given population or the probability of an
event for an individual.
When reliability is considered from the
perspective of the consumer of a
technology or service, actual reliability
measures may differ dramatically from
perceived reliability. One bad experience
can be magnified in the mind of the
customer, inflating the perceived
unreliability of the product. One plane
crash where hundreds of passengers die
will immediately instill fear in a large
percentage of the flying consumer
population, regardless of actual reliability
data about the safety of air travel.
Reliability period of any object is
measured within the durability period of
that object.
Parallel
Serial
Parallel
mixed
Design for Maintainability
Maintenance Accessibility Evaluation
Accessibility is the relative ease with
which a part or piece of equipment
can be reached for service ,replacement
or repair. The lack of accessibility is
maintainability problem and a frequent
cause of ineffective maintenance. The
evaluation may also be performed by
assigning to each maintainability criterion,
a numerical value between 1 to 5 etc
Maintainability Index
Used for software
The maintainability index (MI) is a
compound metric designed at the
University of Idaho in 1991 by Oman and
Hagemeister. The primary aim of the
metric is to determine how easy it will be
to maintain a particular body of code. It's
great claim to fame is that it was validated
in the field by Hewlett Packard in a fairly
extensive trial
Reliability maintainability
availability scalability
In Software
Energy Management and safety
Health & Environment
Electrical
20% to 30% power lost in transmission
Use of proper motor
Operate the transformer in the optimum
capacity
Proper insulation of electric furnaces
Use old ,obsolete or defective assets by
energy efficient ones
Use natural lighting as far as possible
Mechanical
Maintain Proper sharpness of
tools
Proper lubrication of parts
Pumps with proper matching
in terms of head flow and
other parameters
Arrest leakage in water lines
and valves
Safety health and the work
Environment
Safety standards
Accidents very costly
Preventive Measures
Fencing
Boilers and other pressure vessels must
be maintained properly to keep them in
proper order
Proper illumination
Use of protective clothing and gear
Proper training
Tools should be kept in proper place
Reliability Centered
Maintenance (RCM)
Fundamental cause and effect relationship
between scheduled maintenance and
operating reliability This assumption
was based on the intuitive belief that
because mechanical parts wear out, the
reliabilty ofany equipment is directly
related to operating age. It therefore
,followed hat the more frequently
equipment overhauled , the better
protected it was against the likelyhood of
failure.
Nowlan and Heap reached the conclusion
that a maintenance policy based
exclusively on some maximum operating
age would no matter what the age limit
have little or no effect on the failure rate In
separate independent studies ,it was
noted that a difference existed between
the perceived and intrinsic design life for
the majority of equipments and
components . In fact it was discovered that
in many cases equipment greatly exceed
the perceived or stated design life
Maintenance Philosophies
Breakdown
Maintenance
Industrial
Revolution
Preventive or
Change-out
Maintenance
Second
World
War
Predictive or
Condition
Based
Maintenance
Mid 60s
Reliability
Centred
Maintenance
Mid 80s
RCM
Is the optimum mix of reactive, time or
interval-based, condition-based , and
proactive maintenance practices. Fig 100
With the help of computers it is possible to
identify the precursors of failure , quantify
equipment condition and schedule the
appropriate repair with a higher degree of
confidence
Each failure mode is analysed through
decision-logic to ascertain the type of
maintenance needed and its optimum
level
Failure Mode and Effect
Analysis (FMEA)
FMEA is a reliabiliy engineering
method(MIL-STD_1629A-1980)
FMEA is a detailed cause and effect
analysis for failures with failure effects
being categorized according to their
severity
RCM codes and Standards
American Society of Non-Destructive
Testing (ASNT) Recommended practice
Number SNT-TC-1A
American Society for testing and Materials
(ASTM)
ASTM C 1060
ASTM C 1153,E 1186,E 1149
ISO 6781,ISO 3945,
MIL-STD-2194,STD-2173
NAVAIR 00-25-403
RCM
A core process in the development of a
maintenance strategy, SKF's Reliability-
Centered Maintenance (RCM) is
embedded with FMEA, identifying failure
causes and determining applicable and
cost-effective tasks to prevent the failures
where asset criticality is high and
optimization of existing maintenance is
needed. The process determines what is
required for an asset to keep fulfilling its
intended function in its present operating
context. RCM is effective in delivering a
roadmap of appropriate tasks,
frequencies, man-hours and skills mix.
Tero Technology

BHPs Experience
Steel Industry World Wide Review
Man-hours per Liquid Tonne of Steel
Four Best Practice Organisations
Biggest difference Maintenance treated as a
PROFIT CENTRE
BHP was managing Maintenance as
COST CENTRE
BHP Action Plan
Understand Problem
Set Overall Target
Target 40% Reduce in Maint. Cost Per Tonne
in 5 years
Develop Approach for Solution
7 Step Plan
BHPs 7 Step Plan
.1 Re-Education
.2 Re-Define Roles & Responsibilities
.3 Re-Develop Measurements
.4 Provide Processes and Systems
.5 Apply Strategy Based Maintenance
.6 Formalise Continuous Improvement
.7 Focus on Waste Reduction
Total Productive
Maintenance(TPM)
The goal of the TPM program is to
markedly increase production while, at the
same time increasing employee morale
and job satisfaction.
In1970 Nakajima applied the principles of
team work and empowerment in the form
of autonomous maintenance to productive
maintenance
In western style maintenance approach a
centralized maintenance department is
responsible for maintenance of equipment
Zero breakdown
Zero defect
TPM - Objectives
1, To maximize maintenance effectiveness
2, To develop a maintenance system for the
service life of the equipment
3, To involve all the departments that plan,
specify, design or maintain the equipment thus
it includes all technical, engineering, design
production and maintenance employees
To involve personnel from top management to
personnel on the production floor
Around 10 to 40 % of the total cost of the
product is attributed to maintenance
activities and is considered to be integral
part of the business process
TPM implementation statges
Preparation, introduction, implementation
and consolidation
Signature Analysis
Predictive maintenance system is adopted
near the end of the useful life
Potential failure points detected by various
diagnostic techniques such as vibration
noise monitoring,wear particle and
temperature monitoring
Signals received through these machine
health monitoring techniques are grouped
under Signature anlysis
It is similar to ECG in health monitoring
P-F interval is deferent in the case of
different signatures and there fore it is
necessary to consider it before selecting a
perticular system of machine health
monitoring
Ex vibration monitoring P-F interval 1 to 9
minths
Wear particle analysis 1-6 months
While heat P-F interval may be 1-5 days
One factor to be considered is the cost of
condition monitoring system
And the criticality of the equipment
Terotechnology is focused on integrated
management of material sources. Its
purpose is to improve the distribution of
working sources, from purchase, usage,
maintenance and recycling.
Terotechnology represents the technical
and economical aspect, providing
sufficient background for researching
processes of component faults and system
breakdown. Besides it uses advanced
predicting, monitoring and maintenance
scheduling algorithms.
Selection of signature technique
Once various parameters have been
identified the best suited parameter for
carrying out the signature analysis for
machine health monitoring is to be
selected. Best suited but also cost
effective
Exmple of thermometer

System of signal
processing/recording
Reading /recording frequency
Should be put on line
Should be located in a central facility
Training of personnel
They should be educated to identify the
deviation from the normal signature
They should no how to calibrate these
systems

Process of application of
condition monitoring
Detection
Diagnosis
Prognosis
Priscription
Terotechnology
Terotechnology is an interdisciplinary field,
joining mechanical, electrical, diagnostic,
signal processing, and maintenance
experts. Student gains sufficient
knowledge to support maintenance of
complex mechanical sysems.
Tero Technology
Economic life cycle costs approach to
management of plant keeping in view the
reliability, maintainability, efficiency and
full utilization of the plant, equipment and
building in order to achieve maximum
return on investment(ROI)
Factors of tero technology
Design

Purchase
Projects

Operations

Finance
For reliability and
Maintainability
Best buy
Easily operable and
maintainable
Reduce down time
and improve care of
assets
Cost monitoring ,cost
control
Tero technology

Records

Personnel

Maintain proper
records
Selection and training
of operating and
maintenance
personnel
Life cycle costing
Acquisition cost
Product distribution
cost

Operating cost
Maintenance cost
Technical data cost
Inventory cost
Training cost
Retirement & disposal
cost

Tero technology
The designer needs the help of
maintenance manager in evolving designs
that are less prone to breakdowns and are
easy to maintain
Development of methods and procedures
with regard to maintenance of technical
systems.
VED
Vital- absence of which will cause
stoppage of production
An item whose procurement in an
emergency will involve very high cost
An item on which many other processes
depend and which will come to standstill in
case the item breakdown

Essential (E items)
Which cause partial stoppage
Moderate losses
Desirable (D)
Not very significant losses
ABC Analysis
Items are classified on the basis of annual
consumption value
10 to 15 % items accounts for 70 to 80 %
of annual monetary value and they are
classified as A
This is very important to monitor the
useage
FSN analysis
F- fast moving
S- slow moving
N- normal moving
Turn over= annual consump/aver
Inventory
It should be more than 4 for F
2 to 4 for normal
0 to 2 for S
A combination of all three method is
followed.
Category VAF
Vital costly fast moving
There are relatively fewer items in the
spare parts inventory in relation to the
general stores
How ever Economical Order Quantity
(EOQ) may be used
Individual Assignment
Imagine You are appointed as customer
support manager/ maintenance manger
In a company
Example Blue star ,voltas(A/C)
Maruthi, Ford , Hundai, Honda
HP ,Dell,lenpvo,wipro
IFP,Whirlpool,Samsung
FACT, Cochin refinary, India
Cement,Apollo tyres
You have to run this as a profit centre
List the set of activities per one week
What are the tools you may use to monitor
the complaints/manpower
Get a copy of the service slip
What is the man power requirement with
cost and the skill set details, salary etc
What all spare you should have ?
What is the type of Preventive
maintenance you will plan ?
Give your financial projection for the year
2013- 14
What is your down time target ?
How you are planning to reach that level ?
What is your new installation plan ?

Are you going for per call basis or Annual
Maintenance plan ?
What is rate you charge in each case ?
Failure Data Analysis
Design consideration
Maintenance cost consideration
Maintenance staff consideration

Replacement decision
Cost of a machine is Rs 6100/- and its
scrap value is Rs 100/-.Pas record of
maintenance cost is given below
BATH-TUB CURVE

MTBF
MTTF
mean time to failure
, failure rate The first part is a decreasing
. failures known as early
The second part is a constant failure rate,
failures. random known as
The third part is an increasing failure rate,
known as wear-out failures.
Breakdown time distribution
Poissons
Normal
Exponential
Normal distribution

Poissons Distribution

Advanced Maintenance Management: Jose K Puthur RCBS

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