Maintenance Management_Phase2_Maintenance Organization.pptx

Maintenance Management_Phase2_Maintenance Organization.pptx

• 1.
  Maintenance Management Eng. SajjadGazali Phase 2 - Maintenance Organization
• 2.
  Table of Content 1.Types of Maintenance Organization 2. Types of Maintenance Systems A. Breakdown Maintenance B. Planned Maintenance I. Preventive Maintenance II. Corrective Maintenance III. Scheduled Maintenance IV. Condition-Based Maintenance V. Reliability-Centered Maintenance VI. Design-out Maintenance
• 3.
  Types of MaintenanceOrganization Decentralized: o In large sized plants located at different places, inter-unit communication is difficult. o Therefore, in such cases the decentralized type of organization is best suited. o The maintenance department works under the direct control of chief engineer/manager who is in-charge of production. o A better coordination between production and maintenance workforce can be achieved in this type of organization. Centralized: o In relatively small factories where communication between the departments is more easy, the centralized type of maintenance organization is preferred. o The maintenance function works under the direct control of chief maintenance engineer who is responsible for all the maintenance work in the factory. o The responsibilities and accountabilities must be clearly defined for maintenance as well as production personnel to avoid confrontation.
• 4.
  Benefits of CentralizedMaintenance 1. More efficient compared to decentralized maintenance 2. Fewer maintenance personnel required 3. More effective line supervision 4. Greater use of special equipment and specialized maintenance persons 5. Generally allows more effective on-the-job training
• 5.
  Types of Maintenance Systems Maintenancecan be divided into two groups: A. Unplanned Maintenance or Breakdown Maintenance B. Planned Maintenance I. Preventive Maintenance II. Corrective maintenance III. Scheduled Maintenance IV. Condition-Based Maintenance V. Reliability-centered Maintenance VI. Design Out Maintenance Maintenance can be performed in two modes: C. Running Maintenance (Asset is in operation) D. Shut Down Maintenance (Asset is out of service)
• 6.
  Breakdown Maintenance oBreakdown maintenanceis basically the “run it till it breaks” maintenance mode. oNo actions or efforts are taken to maintain the equipment until a component or equipment fails or becomes inoperative. oThe work which is required to be done in the case of an emergency failure, has to be carried out to bring back the equipment to its original working condition. oIn case of risky equipment /systems such as aircraft, elevators and other such items, chances with only breakdown maintenance cannot be taken. oEven though it appears to be an economical proposition, work would greatly suffer if the machine is not restored to operational condition immediately. oIn this type of maintenance, during the repair, no proper care is taken to know the real cause of the breakdown, which in turn may lead to frequent failures of same kind.
• 7.
  Breakdown Maintenance Advantages 1. LessInvestment. 2. Less staff. Disadvantages 3. Increased cost due to unplanned downtime of equipment. 4. Increased labor cost, especially if overtime is needed. 5. Cost involved with repair or replacement of equipment. 6. Possible secondary equipment or process damage from equipment failure. 7. Inefficient use of staff resources.
• 8.
  Planned Maintenance Under thistype of maintenance, the work is planned beforehand to avoid random failures. It decides not only the ‘when’ and ‘what’ of maintenance , but also by ‘whom’ it would be undertaken. To be able to take informed decision and planning of maintenance activities data collection and record keeping is important. Historical data may be used to decide the periodicity/frequency of the maintenance work. Work study/Time study can be done for devising optimal maintenance schedule for the given system.
• 9.
  Preventive Maintenance Preventive maintenanceis the Actions performed 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. Preventive Maintenance is the utilization of planned and coordinated inspections, adjustments, repairs and replacements needed in maintaining an equipment or plant. One of the main objective of the preventive maintenance is to detect and prevent any condition that may cause machine failure before such failure occurs. This makes it possible to plan and schedule the maintenance work without interruption in production schedule and thus improve the availability of equipment.
• 10.
  Preventive Maintenance…(cont.) Following activitiesare taken-up as part of preventive maintenance: i. Routine attention ii. Routine Examination iii. Preventive Replacement Planning and implementation of preventive maintenance system is a costly affair because during inspection all deteriorated parts/components are replaced. However the higher cost of maintenance is usually gets compensated by the prolonged operational life of the equipment.
• 11.
  Corrective Maintenance Corrective maintenancecan be defined as the maintenance carried out to restore the equipment that has stopped working to acceptable standards.
• 12.
  Scheduled Maintenance In thistype of maintenance work, the frequency of maintenance predetermined from experience or from the guidelines given by the equipment manufacturer. The actual maintenance programme is scheduled in consultation with the production department so that the equipment is made available for maintenance work. In this way , the most efficient use of idle time can be made. Though scheduled maintenance is costly as compared to breakdown maintenance, the availability of equipment is enhanced.
• 13.
  Scheduled Maintenance… (cont.) Advantages 1. Costeffective in many capital-intensive processes. 2. Flexibility allows for the adjustment of maintenance periodicity. 3. Increased component life cycle. 4. Reduced equipment or process failure 5. Prolonged life of equipment Disadvantages 6. Catastrophic failures still likely to occur. 7. Labor intensive. 8. Includes performance of unneeded maintenance. 9. Potential for incidental damage to components in conducting 10.Unneeded maintenance.
• 14.
  Condition-Based Maintenance This kindof maintenance is carried out in response to a significant deterioration in the unit or system as indicated by a change in a monitored parameter of equipment or system on its condition or performance. It includes measurements that detect the onset of system degradation (lower functional state), thereby allowing stressors to be eliminated or controlled prior to any significant deterioration in the component physical state. It is also called Predictive Maintenance. A condition-based maintenance policy is most suited to high capital cost equipment and complex replaceable parts.
• 15.
  Condition-Based Maintenance… (cont.) A goodknowledge of failure data is necessary for effective implementation of condition-based maintenance. It is also possible to minimize inventory and order parts, as required, well ahead of time to support the downstream maintenance needs. Advantages 1. Increased component operational life/availability. 2. Allows for preemptive corrective actions. 3. Decrease in equipment or process downtime. 4. Decrease in costs for parts and labor. 5. Better product quality. 6. Improved worker and environmental safety. 7. Improved worker morale. Disadvantages 8. Increased investment in diagnostic equipment. 9. Increased investment in staff training.
• 16.
  Reliability-Centered Maintenance RCM is aprocess used to determine the maintenance requirements of any physical asset in its operating context. Basically, RCM methodology deals with some key issues not dealt with by other maintenance programs. It recognizes that all equipment in a facility is not of equal importance to either the process or facility safety. It recognizes that equipment design and operation differs and that different equipment will have a higher probability to undergo failures than others. RCM is highly reliant on predictive maintenance but also recognizes that maintenance activities on equipment that is inexpensive and unimportant to facility reliability may best be left to a reactive maintenance approach. Identify the equipment to be maintained? What are its functions Identify its Failure Modes & Caused of Failure Identify the consequence of Failure Occurring Rank Potential Failures Produce a maintenance task to prevent/detect each failure
• 17.
  Reliability-Centered Maintenance… (cont.) Advantages 1. Canbe the most efficient maintenance program. 2. Lower costs by eliminating unnecessary maintenance or overhauls. 3. Minimize frequency of overhauls. 4. Reduced probability of sudden equipment failures. 5. Able to focus maintenance activities on critical components. 6. Increased component reliability. 7. Incorporates root cause analysis. Disadvantages 8. Can have significant startup cost, training, equipment, etc.
• 18.
  Design-out Maintenance If themaintenance cost or downtime cost of equipment is high, then the Design Out Maintenance strategy can often be effective. This strategy differs from all the others in that it is a one-off activity, as opposed to a repetitive activity designed to prevent failure. Design Out Maintenance aims to redesign those parts of the equipment which consume high levels of maintenance effort or spares cost or which have unacceptably high failure rates. The high maintenance costs may have been caused by a number of factors, including: Poor maintenance. operation of equipment outside of its original design specification A poor initial design. The Design Out Maintenance strategy can only be implemented effectively if high maintenance cost items can be identified and the reasons for the high cost understood.
• 19.
  THANK YOU