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Industrial Maintenance (Full Notes)
The document elaborates on industrial maintenance, defining it as the practice of ensuring equipment and machines are functional to produce quality products while managing costs. It outlines various types of maintenance, including corrective, preventive, predictive, and reliability-centered maintenance, each with its advantages and disadvantages. Concepts of reliability, breakdown maintenance, and strategies for improving maintenance efficiency are also discussed.
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Industrial Maintenance (Full Notes)
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- 3. Contents 1. Meaning 2. Typesof industrial Maintenance 3. Concept of Reliability in Maintenance 4. Corrective vs. Breakdown Maintenance 5. Concept of Reliability in Maintenance 6. Reliability Improvement 7. References
- 4. Meaning •The technical meaningof Industrial Maintenance is “the practice of keeping the equipment and machines in proper functioning condition to produce quality products”.
- 5. •The Objectives ofindustrial maintenance is to increase plant equipment’s life & keeping all the plant’s assets in good condition at the lowest possible cost •Industrial Maintenance is also called “Plant Maintenance”
- 6. Industrial Maintenance includestwo following actions: 1. Control or prevent the deterioration process leading to failure of a machine or equipment. 2. Restore the object to its operational state through corrective actions after a breakdown or failure.
- 7. Types of industrialMaintenance
- 8. •The design lifeof most equipment requires periodic maintenance. •Belts need adjustment, alignment needs to be maintained, proper lubrication on rotating equipment is required, and so on.
- 9. •E.g.:- a wheelbearing on a motor vehicle, to ensure the main piece of equipment (in this case a car) last for its design life. •In addition to waiting for a piece of equipment to fail (reactive maintenance) the other approaches are preventive maintenance, predictive maintenance, or reliability centered maintenance.
- 10. 1. Breakdown MaintenanceOr Reactive / Real-time Maintenance • Reactive maintenance is concerned with tasks that come after a piece of equipment breaks down. •The advantage of reactive maintenance is that the initial costs are significantly lower. Maintenance tasks are only carried out when a machine is already showing signs of poor performance.
- 12. Advantages 1. Involves lowcost investment for maintenance. 2. Less staff is required.
- 13. Disadvantages 1. Increased costdue to unplanned downtime of equipment. 2. Increased labor cost, especially if overtime is needed. 3. Cost involved with repair or replacement of equipment. 4. Inefficient use of staff resources.
- 14. 2. Preventive Maintenance •Actionsperformed on a time or machine-run-based schedule that detect, preclude, or mitigate degradation of a component or system with the aim of sustaining or extending its useful life through controlling degradation to an acceptable level is Called the Preventive Maintenance. •To optimize the amount of servicing required , perform a more sound analysis with the availability of data and information, such as in a reliability-centered maintenance strategy.
- 16. •Preventive maintenance isa means to increase the reliability of their equipment. •In addition to an increase in reliability, lot of amount will be saved over that of a program just using reactive maintenance. •Studies indicate that this savings can amount to as much as 12% to 18% on the average.
- 17. Advantages 1. Cost effectivein many capital intensive processes. 2. Flexibility allows for the adjustment of maintenance periodicity. 3. Increased component life cycle. 4. Energy savings.
- 18. Disadvantages 1. Catastrophic failuresstill likely to occur. 2. Labour intensive. 3. Includes performance of unneeded maintenance. 4. Potential for incidental damage to components in conducting unneeded maintenance.
- 20. 3. Predictive Maintenance •Predictivemaintenance can be defined as Measurements that detect the onset of a degradation mechanism, thereby allowing causal stressors to be eliminated or controlled prior to any significant deterioration in the component physical state. Results indicate current and future functional capability
- 21. •Independent surveys indicatethe following industrial average savings resultant from initiation of a functional predictive maintenance program: 1. Return on investment—10 times 2. Reduction in maintenance costs—25% to 30% 3. Elimination of breakdowns—70% to 75% 4. Reduction in downtime—35% to 45% 5. Increase in production—20% to 25%.
- 23. Advantages 1. Increased componentoperational life/availability. 2. Allows for pre-emptive corrective actions. 3. Decrease in equipment or process downtime. 4. Decrease in costs for parts and labor.
- 24. Disadvantages 1. Increased investmentin diagnostic equipment. 2. Increased investment in staff training. 3. Savings potential not readily seen by management.
- 26. 4. Reliability-Centered Maintenance(RCM) •RCM aims to avoid failures by analyzing the best actions to take. •RCM takes into account the criticality of an asset alongside potential causes of failure and corresponding corrective actions. •The result is that equipment within the same facility could be assigned different maintenance strategies.
- 28. 5. Corrective Maintenance •Correctivemaintenance is the category of maintenance tasks that are performed to rectify and repair faulty systems and equipment. •The purpose of corrective maintenance is to restore systems that have broken down. Corrective maintenance can be synonymous with breakdown or reactive maintenance.
- 31. How Are CorrectiveMaintenance Needs Identified? •Corrective maintenance orders are typically initiated when an additional problem is discovered during a separate work order. • For example, if a maintenance technician spots an issue during an emergency repair, as part of a routine inspection or in the process of conducting preventive maintenance, that issue can turn into a corrective maintenance order.
- 32. •That corrective maintenancetask is then planned and scheduled for a future time. During the execution of corrective maintenance work, the asset is repaired, restored, or replaced as needed.
- 33. Advantages 1. Reduce emergencymaintenance orders 2. Increase employee safety 3. Reduce service interruptions 4. Extend asset lifetime 5. Decreases downtime
- 34. Disadvantages 1. Unpredictability 2. Interruptionto production 3. Shortened asset lifespan
- 35. How to ReduceCorrective Maintenance 1. Invest in the right technology 2. Invest in your team 3. Train your staff to use tools 4. Automate work order delegation 5. Stock essential tools and equipment
- 37. Corrective vs. BreakdownMaintenance •Corrective maintenance, is focused on rectifying and repairing faulty equipment. •Breakdown maintenance is performed on equipment that is broken, faulted, or otherwise stopped in such a manner as to make the equipment nonoperational.
- 38. •The biggest differenceis that breakdown maintenance works on equipment that is nonoperational. • Corrective maintenance takes place on equipment that is still functioning to some extent but will not function at optimal capacity without the maintenance being performed.
- 39. Concept of Reliabilityin Maintenance •Reliability is the probability of survival under a given operating environment. •For example, the time between consecutive failures of a refrigerator where continuous working is required is a measure of its reliability. If this time is more, the product is said to have high reliability.
- 40. •In a textilemill, generally the light is maintained at a minimum specified level. •To achieve this, let us assume that there are 100 bulbs in use and the guaranteed life time of these bulbs is 5000 hours.
- 41. • If wecollect statistics about the number of bulbs survived till 5000 hours, we can compute the reliability of the bulbs. •In this case,
- 42. •If the numberof bulbs survived till 5000 hours is 80, then we can say that the reliability is 0.8 (i.e., 80/100).
- 43. •This is calledbath-tub curve. •There will be large number of failures in the early period. This is mainly due to nonalignment while shipping the product, or misfit while manufacturing (assembling), or very high initial friction between moving parts, etc. Product Failure Rate
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- 45. •Some of theways of improving systems reliability are listed below: 1. Improved design of components 2. Simplification of product structure 3. Usage of better production equipments 4. Better quality standards 5. Better testing standards
- 47. References •Analyseameter.com •Onupkeep.com •Production and OperationsManagement by S.Anil Kumar, N.Suresh
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