Principles and practices of

Maintenance planning
Semester VIII - ME
Syllabus
1. Basic Principles of maintenance planning Objectives and
principles of planned maintenance activity Importance and
benefits of sound Maintenance systems Reliability and
machine availability, Equipment Life cycle, Measures for
Maintenance Performance: Equipments breakdowns, Mean
Time Between Failures, Mean Time to Repair, Factors of
availability, Maintenance organization, Maintenance
economics.
21 June 2014 2
Maintenance planning
Basic Principles of maintenance
planning
21 June 2014 Maintenance planning 3
21 June 2014
Maintenance planning
4
Maintenance is the
combination of all technical,
administrative and
managerial actions during the
life cycle of an item intended
to retain it in, or restore it to, a
state in which it can perform
the required function
21 June 2014
Maintenance planning
5
Maintenance is the
combination of all technical,
administrative and
managerial actions during the
life cycle of an item intended
to retain it in, or restore it to, a
state in which it can perform
the required function
Life Cycle Component of a Production
System
21 June 2014
Maintenance planning
6
Why Maintenance?
21 June 2014
Maintenance planning
7
1. If an equipment can be designed, manufactured and
used in such a way that it never failed, there would be
no need for preventive maintenance or for repair.
2. Similarly, if all the components of an equipment failed
simultaneously, there would be no need for its repair,
since the whole equipment could then be replaced.
3. Components do have a substantial failure rate, either
due to deficiencies in design, or manufacture or use.
Such components need to be repaired or replaced
immediately to avoid the equipment remaining out of
action.
4. Components have a highly variable life amongst
themselves.

21 June 2014
Maintenance planning
8
1. Repairs also consume
time and reduce
equipment availability.
2. Some design features
greatly ease and thereby
speed up the process of
repair itself, thus
diminishing the down
time of the equipment.
3. Some design features
can increase, while
other features decrease
the repair time
dramatically
Introduction to Maintenance
21 June 2014
Maintenance planning
9
1. Preserving Physical assets Vs. Preserving
functions of assets.
Preserving inherent reliability.
The asset should continue to do what it is expected to
do.
Focus on functions.
2. 1960s : Trend towards Maintenance Prevention.
3. 1970s : Change in trend due to inflation, high cost
assets, competition, rapid change of technology.
Enhance useful life of equipment.
4. Maintenance is an investment.
5. Maintenance is Force multiplier.
Purpose of Maintenance
21 June 2014
Maintenance planning
10
1. Reduce business risks.
2. Ensure high level of
Availability
Reliability
Operability
3. Support end user in the various stages of
equipment life cycle.
4. Ensuring safety
5. Reduce pollution/ environmental effects.
6. Cost reduction and cost control.
7. Waste reduction and waste recovery.

Basic Maintenance Functions
21 June 2014
Maintenance planning
12
1. Replace
2. Repair
3. Overhaul
4. Rebuild/
Reclamation
5. Service



6. Lubricate
7. Inspect
8. Test / Examine
9. Adjust
10. Align
11. Calibrate
12. Install



FUNTIONS OF A MAINTENANCE
DEPARTMENT
21 June 2014
Maintenance planning
13
1. Maintenance of installed equipment and facilities
2. Installations of new equipment and facilities
3. PM tasks Inspection and lubrication of existing
equipment
4. CM tasks monitoring of faults and failures using
appropriate techniques
5. Modifications of already installed equipment and
facilities
6. Management of inventory
7. Supervision of manpower
8. Keeping records
9. Advice on Procurement, Usage and Discard.
Importance of sound Maintenance
System
21 June 2014
Maintenance planning
14
1. Maintenance costs, are normally a major portion of the total
operating costs in most plants.
Studies indicate that 30% of Maint costs are wasted through ineffective
maintenance management methods
2. The dominant reason for this ineffective management is the lack of
factual data that quantify the actual need for repair or maintenance
of plant .
Maintenance scheduling has been and in many instances still is
predicated on statistical trend data or on the actual failure of plant
equipment.
3. Impact of the maintenance operation on product quality, production
costs, and more importantly on bottom-line profit.
4. Technology and instrumentation are now available for effective
maintenance based on condition monitoring.
5. It is now possible to reduce or eliminate unnecessary repairs,
prevent catastrophic machine failures, and reduce the negative
impact of the maintenance operation on the profitability of
manufacturing and production plants.
ELEMENTS OF EFFECTIVE
MAINTENANCE MANAGEMENT
21 June 2014
Maintenance planning
15
1. Maintenance Policy
2. Control of materials
3. Preventive Maintenance
4. Condition Monitoring
5. Work Order
6. Job planning
7. Priority and backlog control
8. Data recording system
9. Performance measurement measures or
indices
21 June 2014
Maintenance planning
16
GoAir is currently operating at 21
cities with 156 daily flights and
approximately 1092 weekly flights
11 aircrafts

Ahmedabad, Bagdogra, Bengaluru, Chandigarh,
Cochin, Delhi, Goa, Guwahati, Jaipur, Jammu,
Kolkata, Leh, Lucknow, Mumbai, Nagpur, Nanded,
Patna, Port Blair, Pune, Ranchi and Srinagar.
21 June 2014
Maintenance planning
17
GoAir is currently operating at 21
cities with 156 daily flights and
approximately 1092 weekly flights
11 Aircrafts

Ahmedabad, Bagdogra, Bengaluru, Chandigarh,
Cochin, Delhi, Goa, Guwahati, Jaipur, Jammu,
Kolkata, Leh, Lucknow, Mumbai, Nagpur, Nanded,
Patna, Port Blair, Pune, Ranchi and Srinagar.
21 June 2014
Maintenance planning
18
Equipment Life Cycle
21 June 2014
Maintenance planning
19
Needs and
Requirement
s
Desig
n
Production Use
Retirement
Conceptual Design
Preliminary Design
Detailed Design
Operation
Maintenance
Support
Manufacture
Assembly
Framework of System Design
21 June 2014
Maintenance planning
20
DESIGN
OF THE
PRODUCT
Produce
ability
Requirement
Functional
Requirements
Safety
Requirement
Strength
Requirement
Reliability
Requirement
Operability
Requirement
Maintainability
Requirement
Environmental
Requirements
Cost Time
21-Jun-14
Product Design and Development
21
Product Life Cycle : Demand Curve
1. Stages of
Product Life
Cycle
1. Introduction
2. Growth
3. Maturity
4. Decline
2. Facility and
process
investment
depends on life
cycle.
Time
D
e
m
a
n
d

o
f

p
r
o
d
u
c
t

1
2
3
4
21 June 2014
Maintenance planning
22

Most products
go through
three distinct
phases from
product
inception to
wear out.

Bath Tub Curve shows a typical life cycle
curve for which the failure rate is plotted as
function of time.
The Bath Tub Curve of Eqpt Failure Rate
21 June 2014
Maintenance planning
23
1. Field failures do not generally occur at a uniform rate, but
follow a distribution in time commonly described as a
"bathtub curve."
2. The life of a device can be divided into three regions: Infant
Mortality Period, where the failure rate progressively
improves; Useful Life Period, where the failure rate remains
constant; and Wearout Period, where failure rates begin to
increase.
The Bath Tub Curve (Cont..)
21 June 2014
Maintenance planning
24
1. Units that pass the Infant Mortality Period have a
high probability of surviving the conditions provided
by the system and its environment.
2. Failures that occur during the Useful Life Period
are residual defects surviving Infant Mortality,
unpredictable system or environmental conditions,
or premature wear out.
3. Wearout failures are generally associated with
such failure mechanisms as metal migration, hot
electron effects, wirebond intermetallics, or
thermal fatigue.

Life Cycle Costing
21 June 2014
Maintenance planning
25
The sum total of direct, indirect, recurring,
non-recurring and other related costs incurred
or estimated to be incurred in the design,
development, production, operation,
maintenance and support of the equipment
system over its anticipated useful lifespan.