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Maintenance Policies:: Breakdown Maintenance or Reactive Maintenance
Maintenance Policies:: Breakdown Maintenance or Reactive Maintenance
Reliable plant capacity may be defined as an investment in maintenance which helps in producing
product and makes a company cost competitive.
Company would prefer to have machines that will run perform well without any human intervention
when any new machine is to be installed it is needed to have an intellectual group. To work in team
which is first step in maintanence effectiveness? The second step is to be proactive maintenance
once the machine is installed and operating.
Breakdown maintenance
Planned maintenance
1. Preventive
2. Corrective
3. Predictive
4. Condition based
5. Reliability centered.
Maintenance approach
The equipment is allowed to function operate till no failure occurs i.e., no maintenance work is
carried out in advance to prevent the failure .as long as the equipment is functioning at a minimum
acceptable is ineffective and extremely expensive . The following factors contribute to high
maintenance costs
1. Poor planning
2. Incomplete repair
Limitations
1. Most repairs are poorly planned due to time constraints caused by production and plant
management. Thus will cost three t fur times than the same repair when it is well planned.
2. This approach focus only n repair t the symptoms of failure and not on the rast cause of
failure. This results only in increases in the frequency of repair and correspondingly the
maintenance costs.
Preventive Maintenance:
It id designed for day to day maintenance like cleaning, inspection, lubricating, retightening etc to
repair the healthy condition of equipment.
1. It maintain the equipment in good condition t preventing them from bigger problems
2. Prolongs the effective life of the equipment
3. Detects the problem at earlier stage.
4. Minimize / eliminates the rework/scrap and helps in reducing the process variability.
5. Significantly reduces unplanned down time.
Corrective Maintenance:
1. Eliminates breakdown
2. Eliminates deviations from optimum operating conditions
3. Eliminates unnecessary repairs.
4. Optimize all critical plant systems.
1. Existence of trained full time maintenance planners for accurate identification of root cause of
all incipient problems.
2. Properly trained craftsman with necessary skills to complete the repair of each incipient
problem.
3. Standard maintenance procedure for recurring repair and maintenance task.
4. A through verification process to ensure the completion of repair.
Predictive maintenance:
Predictive maintenance supplies the necessary information which helps to improve /increase.
RCM is one of the established systematic and a step by step instructional tool for
selecting applicable and appropriate maintenance operation types. RCM helps t prevent
or find those failures early. The rough of a RCM is as follows.
1. Target products or system of maintenance should be clearly identified and necessary
data should be collected.
2. All possible failures and their effect on target product or system are systematically
analyzed {FMEA}.
3. Preventive or corrective maintenance operations are considered selection of
operations is done based n Rational Calculation of Effectiveness of such operation
for achieving required maintenance quality such as reliability, cost, etc.
Applications of RCM
Implementation of TPM
Stage 1- Initialization
Stage4- Institutionalization
Stage 1
Stage 2
Stage 3
Implementation Stage:
The following activities which are familiarly called as pillars of TPM are carried out
Stage4
Institutionalizing Stage
Once the action team are familiar with the TPM process and have experienced
success with small level problems and then high and complicated problems the company can apply
for pm award.
Pillars of TPM
Pillars of TPM
Quality Maintenance
Training
Office TPM
Safety Heathand
Environment
5S
Planned Maintenance
KOBISTU KAIZEN
Pillars 1-5S
a) Policy
1. Uninterrupted operation of Equipments
2. Flexible Operators to operate and maintain other equipment
3. Eliminating the effects at source through active employee production
4. Stepwise implementation of JH activities
b) JISHU HOZEN Targets
1. Reduce oil consumption by 50%
2. Reduce process time by 50%
3. Increase use of JH 50%
c) Steps in JISHU HOZEN
1. Training Employee
2. Initial cleanup of Machines
3. Taking Counter Measures
4. Fixing tentative JH standards
5. General Inspection
6. Autonomous Inspection
7. Standardization and
8. Autonomous Management
Pillar 3-KAIZEN
KAI ea ha ge a d )EN ea s good for the etter . Basi ally KAI)EN is for small
improvements but carried out in a continual basis and involve all people in organization.
Customer
orientation
Process
Automation Team
work
Elements of KAIZEN
TPM
JIT Just in
time
Employee/ Quality
Top circle
Sixteen Major losses in an Organisation
Policy:
1) Processing loan
2) Cost loss including in areas such as procurement, accounts, marketing sales leading
to high inventories
3) Communication loss
4) Idle loss
5) Setup loss
6) Accuracy loss
7) Office Equipment breakdown
8) Communication channel breakdown
9) Time spend on Retrieval of information
10) Non Availability of correct online stock status
11) Customer complaint due to logistics
12) Expenses on Emergency dispatch/ purchases
P= Production output cost due to want of material, manpower, productivity, production output cost
due to want of tools.
Q= Mistakes in preparation of cheques, bills, invoices, payroll, customer return/ warranty attribute
to BOPS.
C= Buying cost/ unit produced, cost of logistics- Inbound/ Outbound cost of carrying Inventory, cost
of communication
1) Zero Accident
2) Zero Health damage
3) Zero fires
planner
operator
schedules
Stakeholders of
Operation Maintenanc
superinde e
Storage craftsman
incharge
Repair
1) Inspection
2) Repair
3) Overhauling
To create Maintenance Scheduling Program the various maintenance activities may be classified into
four categories which are as follows:
I. Inspection(I)
II. Minor Repair(R1)
III. Medium or Major(R2) and
IV. Overhauling(O)
R2 I
I R1
R1 R2
Lubrication:
The primary objective of lubrication is to reduce wear and heat between contacting surfaces
in relative motion. By means of lubrication coefficient of friction(which depends on area of contact
and amount of load acting) could be reduced and in turn heat and wear of the surfaces
Lubricants are available in liquid, solid and gaseous form. Solid lubricants(Soap. Mica,
molybdenum-disulphide etc) are used for industrial application. When oil or grease are nt
suitable. Graphite is used when the loading at the contact points is heavy.
Methods of Lubrication
The following are the various methods of lubrication normally used for Industrial application
a. Hydrostatic Lubrication
b. Hydrodynamic (or) Fluid Film Lubrication (or) Thrust Bearing
c. Boundary Lubrication
d. Elasto hydrodynamic Lubrication (EHD)
e. Extreme Pressure (EP) Lubrication
Where R=
R is in between 5 and less than or equal to 100 for fluid film lubrication