ENGG ZC242:

Maintenance & Safety

BITS Pilani
Pilani Campus

Girish Kant
Department of Mechanical Engineering
ENGG ZC242, Maintenance and Safety,
05/08/2014, Lecture-2

BITS Pilani
Pilani Campus

Introduction to Maintenance
Systems
Chapter 1, Lecture -2

Learning Objectives
Maintenance Objectives/Scope and Benefits/Policies

Maintenance as Business Proposition

Maintenance Philosophy
Types of Maintenance Systems

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Maintenance Objectives
Operational

Maximum operating efficiency of plant

Maximum availability of plant
High Quality performance
Safety
To maintain a plant clean & good appearance
To extend Plant life to the last limit
To reduce environmental impact due to machinery etc
To provide service that will avert all breakdowns at all times at any cost.

Cost
Minimize maintenance expenditure and maximize profits
To provide activities with in the limits of budgetary control

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Maintenance Benefits
Financial

Organizational
Technical
Human
Customer relations

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Financial Benefits
Extended Plant Life

Uninterrupted production
Improved quality of production
Reduced production delays
Reduced cost of repairs

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Organizational Benefits
Co-ordination between production and maintenance

Man power planning

Planning of deliveries

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Technical Benefits
Improved equipment suitability

Build up of technical data

Improved maintenance schedules
Improved plant condition

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Human considerations
Benefits
Increased Safety

Improved House keeping

Less friction between relationships

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Customer relationship
Benefits
Reliable delivery calls

Show case house keeping

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Maintenance Policy
Scope and limits of maintenance

Type and level of service expected

Responsibilities to management
Personal Practices
Trade union contracts
Budget and financial controls

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Maintenance Functions
Primary Functions

Maintenance of existing plant equipment

Maintenance of existing plant buildings and grounds
Equipment inspection and lubrication
Utilities generation and distribution
Alterations and new installations

Secondary Functions

Storekeeping
Plant protection
Waste disposal
Salvage
Insurance
Other services

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What does maintenance really

do?
Repair, lubrication, overhaul, inspection, replacement of
parts
Training of the maintenance staff
Training of the production staff
Testing parts for suitability
Planning of servicing schedules
Improvement and modifications of plant
Production of spare parts

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Maintenance as Business
Proposition
The maintenance costs continue to capture the attention
of senior management as the investment and reliability in
assets become increasingly greater.
The business unit concept
Automation
Maintenance cost reduction

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Maintenance as Business
Proposition

Business unit concept

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Maintenance Philosophy
Most people think of the maintenance function as:

Fixing things that break.

Keeping things looking good.

Keeping things from breaking.

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Types of Maintenance
Systems

Breakdown
Reactive
Preventive
Predictive

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Planned Maintenance
Essential Care(EC): This includes preventing failures
from occurring with tasks such as detailed cleaning,
lubrication, alignment, balancing, operating procedures,
adjustments, and installation procedures.
Fixed-Time Maintenance(FTM): It constitutes all
replacements that are done on a fixed schedule
regardless of condition, e.g. programmed replacements
and overhauls
Condition monitoring(CM): It constitutes all inspections
from simple subjective tasks such as look, listen, feel,
smell etc. to objective tasks such as vibration analysis,
oil-sampling, ultrasonic leak detection, pressure checks,
current readings etc.
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Why Preventive Maintenance?

A breakdown could be catastrophic
An unexpected breakdown is more difficult to manage
than a planned shutdown
PM not only prevents breakdown but also extends
equipment life

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Preventive Maintenance
Programmme Risks
Damage to an adjacent equipment during a PM task.
Damage to the equipment receiving the PM task.
Damage during the performance of an inspection,
repair, adjustment or installation of a replacement part.
Installing material that is defective, incorrectly installing
a replacement part or incorrectly reassembling material.
Reintroducing infant mortality by installing new parts or
materials.
Damage due to an error in reinstalling equipment into its
original location.
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Preventive Maintenance
Program
Identify the critical equipments
List the subsystems and parts for the identified
equipments
Determine the preventive maintenance procedure for
each of the subsystem and parts
Prepare a details work instruction for each procedure
Fix the frequency for each activity
Prepare a PM Calendar for the plant

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Preventive Maintenance

Preventive Maintenance Flow chart

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Key Machine Elements

Bush bearing
Roller / Ball bearing
Gear assembly
Belt & Pulley
Chain & Sprocket
Key
Spline
Clutch
Lead-screw & Nut
Coolant system
Lubrication system
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Key Machine Elements

Compressed air system

Chip conveyer system
Machine spindle
Guide surfaces
Work holding devices
Tool holding devices
Fasteners
Hydraulic system
Seals & Gaskets
Pumps
Motors
Contactors
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Proactive Maintenance
If a disease is pinpointed and eliminated long before any
symptoms occur in your body, it would save your money
in doctor bills and keep you out of hospital in the long
run.
Proactive maintenance commissions corrective action
aimed at the source of failure.

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Predictive Maintenance
The condition of the equipment or machinery is predicted
by observing the signals it emits based on which the
maintenance action is taken
This maintenance is also called condition monitoring
The monitoring can be done online or offline

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Predictive Maintenance

Predictive Maintenance Flow chart

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Summary
Comment on the following statements
Maintenance is a necessary evil
Maintenance is a bottomless pit for expenses
Maintenance is known as Time lag effect

Maintenance is a composite function

Lesser the demand better the service
What type of conditions prevailing with in the company that
affect the demand upon the maintenance department?
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Thanks

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