Preventive Maintenance
Presented by:
Mario Hany
Ahmed Essam
Alaa Faik
Ihab Hassan
Hany Ayad
Maintenance
Maintenance is a set of organized activities that are carried out in order to keep an
item in its best operational condition with minimum cost acquired.
the work of keeping something in proper condition; upkeep. This would imply that
maintenance should be actions taken to prevent a device or component from failing or
to repair normal equipment degradation experienced with the operation of the device
to keep it in proper working order
Types of Maintenance
Maintenance may be classified into four categories:
(some authors prefer three categories- scheduled and preventive
maintenances are merged)
Corrective or Breakdown maintenance
Predictive (Condition-based) maintenance
Scheduled maintenance
Preventive maintenance
Corrective or Breakdown Maintenance
Corrective or Breakdown maintenance implies that repairs are made after the
equipment is failed and can not perform its normal function anymore
Quite justified in small factories where:
Down times are non-critical and repair costs are less than other type of
maintenance
Financial justification for scheduling are not felt
Disadvantages of Corrective
Maintenance
Breakdown generally occurs inappropriate times leading to poor and hurried
maintenance
Excessive delay in production & reduces output
Faster plant deterioration
Increases chances of accidents and less safety for both workers and machines
More spoilt materials
Direct loss of profit
Can not be employed for equipment regulated by statutory provisions e.g.
cranes, lift and hoists etc
Predictive (Condition-based)
Maintenance
In predictive maintenance, machinery conditions are periodically monitored
and this enables the maintenance crews to take timely actions,
such as
machine adjustment, repair or overhaul
It makes use of human sense and other sensitive instruments, such as
audio
gauge, vibration analyzer, amplitude meter, pressure, temperature and
resistance strain gauges etc.
Unusual sounds coming out of a rotating equipment predicts a trouble
An excessively hot electric cable predicts a trouble
Simple hand touch can point out many unusual equipment conditions and thus
predicts a trouble
Scheduled Maintenance
Scheduled
maintenance is a stitch-in-time
incorporates
inspection
lubrication
repair and overhaul of equipment
If
neglected can result in breakdown
Generally followed for:
overhauling of machines
changing of heavy equipment oils
cleaning of water and other tanks etc.
procedure and
Preventive Maintenance (PM)
Principle Prevention is better than cure
Procedure - Stitch-in-time
It
locates weak spots of machinery and equipments
provides them periodic/scheduled inspections and minor repairs to reduce the
danger of unanticipated breakdowns
What really should PM focus on?
Cleaning
Found through testing
Lubrication
and inspection
And correcting deficiencies
Predetermined parts replacement should be minimal and done only where
statistical evidence clearly indicates wear-out characteristics
Maintenance Costs
Cost
Breakdown Cost
Maintenance
Commitment
Maintenance Costs
Cost
PM Cost
Breakdown Cost
Maintenance
Commitment
Maintenance Costs
Cost
Total Maintenance Cost
PM Cost
Breakdown Cost
Maintenance
Commitment
Maintenance Costs
Cost
Total Maintenance Cost
PM Cost
Breakdown Cost
Optimal
Maintenance
Commitment
Strategic Importance of
Maintenance and Reliability
Failure has far reaching effects on a firms
Operation
Reputation
Profitability
Dissatisfied customers
Idle employees
Profits becoming losses
Reduced value of investment in plant and
equipment
Maintenance and Reliability
The objective of maintenance and
reliability is to maintain the capability
of the system while controlling costs
Maintenance is all activities involved in
keeping a systems equipment in
working order
Reliability is the probability that a
machine will function properly for a
specified time
Important Tactics
Reliability
1. Improving individual components
2. Providing redundancy
Maintenance
1. Implementing or improving preventive
maintenance
2. Increasing repair capability or speed
Maintenance Strategy
Employee Involvement
Information sharing
Skill training
Reward system
Employee empowerment
Maintenance and Reliability
Procedures
Clean and lubricate
Monitor and adjust
Make minor repair
Keep computerized records
Results
Reduced inventory
Improved quality
Improved capacity
Reputation for quality
Continuous improvement
Reduced variability
Figure 17.1
Failure Classification
1. Persistence failure classifications:
Intermittent.
Permanent.
2.Degree of failure classification
Complete
Partial
(system).
(subsystem).
3. Deterioration rate classification
Sudden.
Gradual.
The Structure of maintenance systems
Centralized maintenance system
Decentralized maintenance system
Combined centralized decentralized maintenance systems.
Example
Frequency of
breakdown
Number of breakdowns
Frequency of occurrence
0
1
2
3
.20 .30 .40 .10
If the average cost of a breakdown is $1,000, and
the cost of preventative maintenance is $1,250
per month, should we use preventive
maintenance?
Example
Number of
Breakdowns
0
1
2
3
Frequency of
Occurrence
.20
.30
.40
.10
1.00
Expected number of
Breakdowns
0
.30
.80
.30
1.40
Expected cost to repair = 1.4 breakdowns per month X $1000 = $1400
Preventive maintenance = $1250
PM results in savings of $150 per month
Determining the Size of Repair Crews
Problem:
A factory has 200 machines and the maintenance engineer
supervises the repair crews who repair malfunctioning
machines. The maintenance policy is to repair the broken
down machine and bring back in production within 2 hours
on the average. If average breakdown rate is 3.5
machines/hour and each repair crew can repair 0.25
machine per hour on the average. How many repair crews
are required ?
Solution
The formula for average repair rate () is
1
ts = ----------
or = + 1/ ts
-
Where = repair rate
= arrival rate of malfunctioning machines
ts = average time arrivals in the system
Required average repair rate
= 3.5 + 1 / 2 = 4 machines / hour
No. of Crews
= machines/hour a crew can repair
= 4 0.25 = 16 repair crews required
Catastrophic failure
TheDeep water Horizondrilling rig explosionrefers to the April 20, 2010
explosion.
24
9/4/15
9/4/15
25
Advantages of PM
Advantages:
Reduces
Loss
odd-time repair and reduces over time of crews
Greater
Lower
Less
break down and thereby down time
safety of workers
maintenance and repair costs
stand-by equipments and spare parts
Better
product quality and fewer reworks and scraps
Increases
plant life
Increases
chances to get production incentive bonus
Summary
PM is not difficult to achieve.
It is an essential part for cost reduction
There is an element of risk involved in PM
Careful planning and execution will reduce the risk of PM
The biggest benefits of a PM program occur through painting, lubrication,
cleaning and adjusting, and minor component replacement to extend the life of
equipment and facilities.
Thank You
