Maintenance

KULBHUSHAN
Regn No 11110182

Introduction:
Plant maintenance is an important service

function of an efficient production system.

It helps in maintaining and increasing the
operational efficiency of plant facilities.
Maintenance is the procedure of finding the
faults in any equipment/Machine and also
removal of fault.
It may be before the breakdown or after the
breakdown.

Plantmaintenanceusually

refers to the
methods, strategies, and practices used to
keep
an
industrial
factory
running
efficiently. This can include anything from
regular checks of equipment to make sure
they are functioning properly.
The general aim ofplantmaintenanceis to
create a productive working environment
that is also safe for workers.

Maintenance Objectives:
To increase functional reliability of

production facilities.
To maximize the useful life of the
equipment.
To maximize production capacity from the
given equipment.
To minimize the total production cost.
To minimize the frequency of interruption in
production by reducing breakdowns.
To enhance the safety of the manpower.

Maintenance objective

Importance of maintenance
It helps in identify the cause of failure , e.g

whether the failure is due to design defect,

or a wear out failure.
It also helps in deciding the type of
maintenance and maintenance decision like
replace and repair.
It
provides the necessary information
regarding the life and reliability of the
equipment.
With the help of this tool spare parts
management got initiated.

Different type of
maintenance:

Planned MaintenanceIn planned maintenance the maintenance

action is carried out with some fore thoughts,
prior planning , record keeping and control
action. These can be further classified as :Preventive maintenance
Corrective maintenance
Predictive maintenance

 It is based upon the principle that prevention is

better than cure.

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.
Or 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.
It has three types
Running maintenance
Scheduled maintenance
Shut down maintenance

Running maintenance:
Running maintenance which includes those

maintenance activities that are carried out

while the machine or equipment is running.
Example lubrication, adjustment of nuts
and screws, tightening of loose nut and
bolts.

Scheduled Maintenance:
Scheduled

Maintenanceis any variety of

scheduled maintenance to an object or item of
equipment.
Specifically,
Planned
Maintenance
is
a
scheduled service visit carried out by a
competent and suitable agent, to ensure that
an item of equipment is operating correctly and
to therefore avoid any unscheduled breakdown
and downtime.
Good
example
of
PM
program
iscarmaintenance. After so many kilometers or
miles oil should be changed, parts renewed.

Shut Down Maintenance:

Which is a set of preventive maintenance activities

that are carried out when the production line is in

total stoppage situation.
These are performed generally after three or six
months.
These involves the inspection of plant items which
are known or suspected to occur.

Corrective maintenance:
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.

It also include the different types of actions like

typical adjustment of redesign equipment.

The difference between corrective maintenance

and preventive maintenance is that for the

corrective maintenance, the failure should occur
before any corrective action is taken.

It is of two types
1.
2.

Breakdown maintenance
Shutdown maintenance

Breakdown Maintenance:
It is an emergency based policy in which the

plant or equipment is operated until it fails and

then it is brought back into running condition
by repair.
The maintenance staff locate any mechanical,
electrical or any other fault to correct it
immediately.
It is feasible for the small factories where
1. There are few types of equipment.
2. Machine and equipments are simple and does

not require any specialist.

3. Where sudden failure does not cause any
serious financial loss.

Predictive maintenance:
As

the names implies it involves the

prediction of the failure before it occurs,
identifying the root cause for those failures
symptoms and eliminating those causes
before they result in extensive damage of
the equipment.
Type
ofmaintenanceperformed
continuously or at intervals according to
therequirementsto
diagnose
and
monitoraconditionorsystem.
Also
calledcondition based maintenance.

Unplanned Maintenance:
Maintenance action which is carried out

without any fore thoughts or prior planning is

called unplanned maintenance.
Emergency maintenance is one of the
example of unplanned maintenance.
In this type of maintenance the maintenance
action is executed with the help of all
available maintenance resources in least
possible time, without any major time lag.
Examples are gas leakage in chemical plant,
fire hazards, breakdown of boiler, turbine etc.

Nature of maintenance
problem:

General classification Maintenance

problem.
Mechanical Failure

Worn out bushes and bearings and other moving parts.

Fatigue of machine members
Creep of material at high temp
Excessive forced vibration, misalignments etc.

Thermal Failure

Overheating of the component

Lack of lubrication
Inadequate of cooling
Electrical insulation failure

Chemical Failure

Highly corrosive fluids containing abrasive particles

Failure of protective linings like glass , rubber etc.

Classification maintenance
problem based on time span:
Short run production problem

Maintenance problem which are carried out in a sort

period of time are known as short run production
system. It may be hourly, daily ,weekly and monthly.
Example:Hourly- inspection of correct lubricant, level of coolant,
sharpness of cutting tool.
Daily- cleaning of m/c, tightening of nuts, correct
cooling, inspection of various indicators, minor
adjustment of parts.
Weekly- Major adjustment, lubrication, tightening of
parts.
Monthly- checking for insulation, corrosion, safety
guards, checking of worn-out and distorted parts.

Procedure of Preventive
maintenance

1. Job identification by preparing

of facility engineer
The very first step of PMP is to prepare the

facility register which defines that what to be

maintained.

2. Preparation of maintenance
schedule
In this step we prepare a maintenance

schedule. It is simply a comprehensive list of all

the incident and their time of incidence.
It gives the useful information regarding the
method, time and place of maintenance work,
besides it also provides secondary information
about maintenance man power requirement
etc.
It
gives the various details regarding
maintenance like what, when, how, where.

3. Preparation of history card

It not only gives the useful information about the

result of maintenance events but also furnishes

the essential details regarding the uses of
machines, free of failures and failure modes.

4. Preparation of Job
specification

In this step the job specification is prepared. It

is simply a document which provide the

essential
information
regarding
the
maintenance work to be done.
In general practice these job details are
specifications compiled from maintenance
schedules.
They are a means of communicating the
engineers requirement to guide the workers.

5. Preparation of maintenance
Programming
It is a sequential list which allocates specific

maintenance work to a specific period.

In
order to apply the job specification, the
maintenance programme is generally prepared
for long run when the machines/ equipment are
to be inspected.
It is not a good practice because an industry can
not prepare a long run production well in
advance since too many factors arise and they
will result into change in production and
maintenance requirement.
It presents a overall picture of present and
future maintenance commitments.

6. Preparation of weekly/Monthly
maintenance programmes
The next step under plant maintenance procedure

is to prepare the weekly/ Monthly maintenance

programmes. The maintenance programmes
include the following topics.
1. Reconditioning or replacing the lubricating oil
2. Repairing and replacing worn out parts and tools etc
3. Checking all the electrical connections of the system
4. Checking the control system
5. Checking the performance of each parts.
6. Cleaning the interior parts like spark plugs, filters

radiators, crankcase, cylinders etc.

7. It will lie under the long run maintenance
programmes.

7. Preparing of inspection
report
This

step is followed after the maintenance

programme is over. This is simply a document which
furnishes
the
useful
information
about
the
maintenance inspections which were performed in
the past.

8. Preparing of maintenance
request
The

next step under plant maintenance

procedure is to preparation of maintenance
request. It is simply a document or various
maintenance suggestions and recommendation
given by the inspection report. Suggestions are
the useful feedback information that comes
from users end workers.

9. Feedback mechanism
In the last step the application of corrective

and control actions are available on the

basis of feedback mechanism. These
corrective actions should be applied to
respective plant facilities at the initial stage
of maintenance planning or design.

Schedules of preventive
maintenance:
It is simply a comprehensive list of all the

incident and their time of incident. It gives

the following useful information regarding
the maintenance work.
What is to be done or maintained?
ii. How is to be maintained?
iii. When is to be maintained?
Besides this it may also provide the secondary
information
regarding
the
place
of
maintenance
and
maintenance
requirement.
i.

Maintenance Strategy:
A maintenance strategy defines the rules for the

sequence of planned maintenance work. It

contains general scheduling information, and can
therefore be assigned to as many maintenance
task lists (PM task lists) and maintenance plans
as required. A maintenance strategy
containsmaintenance packagesin which the
following information is defined:
The cycle in which the individual work should be
performed (for example, every two months, every
3,106.86 miles, every 500 operating hours)
Other data which affects scheduling

Structure:
A maintenance strategy consists of:
Strategy header: Name of the strategy,
Scheduling parameters: Contain the
scheduling data for the respective
maintenance strategy, which influence the
scheduling of maintenance plans.
Scheduling indicators
Maintenance packages

Scheduling Indicators:
Within a maintenance strategy, you can use
different scheduling indicators to specify the
type of scheduling you require or to define a
cycle set:
Time-based(for example, every 30 days)
Time-based by key date(for example, every
30 days on the 30th day of the month)
Time-based by factory calendar(for example,
every 30 working days)
Performance-based(for example, every 50
operating hours)

Maintenance Packages:
Maintenance activities that must be

performed at a particular date or point in

time are combined into maintenance
packages

Total Productive
Maintenance (TPM)

Totalproductivemaintenance(TPM)originatedinJapanin

1971asamethodforimprovedmachineavailabilitythrough
betterutilizationofmaintenanceandproductionresources
Itcanbeconsideredasthemedicalscienceofmachines.
TotalProductiveMaintenance(TPM)isamaintenance
programwhichinvolvesanewlydefinedconceptfor
maintainingplantsandequipment.
ThegoaloftheTPMprogramistomarkedlyincrease
productionwhile,atthesametime,increasingemployee
moraleandjobsatisfaction.

TPM brings maintenance into focus as a

necessary and vitally important part of

the business.
It is no longer regarded as a non-profit
activity. Down time for maintenance is
scheduled as a part of the
manufacturing day and, in some cases,
as an integral part of the manufacturing
process.
The goal is to hold emergency and
unscheduled maintenance to a minimum.

Why TPM :
TPM was introduced to achieve the following

objectives. The important ones are listed below.

Avoid wastage in a quickly changing economic
environment.
Producing goods without reducing product
quality.
Reduce cost.
Produce a low batch quantity at the earliest
possible time.
Goods send to the customers must be non
defective.

Conclusion:
Today, with competition in industry at an all

time high, TPM may be the only thing that

stands between success and total failure for
some companies.
It has been proven to be a program that
works. It can be adapted to work not only in
industrial plants, but in construction, building
maintenance, transportation, and in a variety
of other situations.
If everyone involved in a TPM program does
his or her part, an unusually high rate of
return compared to resources invested may
be expected.