IV UNIT PPT

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Maintenance Policies:
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.

Basically there are two types of maintenance tasks

 Breakdown maintenance
 Planned maintenance
1. Preventive
2. Corrective
3. Predictive
4. Condition based
5. Reliability centered.

Maintenance approach

Breakdown maintenance Planned maintenance

preventive corrective predictive Condition Reliability

bre centered
based

Breakdown Maintenance or Reactive Maintenance

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.

Benefits of preventive Maintenance:

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:

The main objectives of this program are to

1. Eliminates breakdown
2. Eliminates deviations from optimum operating conditions
3. Eliminates unnecessary repairs.
4. Optimize all critical plant systems.

Prerequisites f corrective maintenance:

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 as regard to maintenance management based on need will provide
necessary data for scheduling of preventive and corrective maintenance tasks. It reduces the
unscheduled breakdown and also it assures that the machine acceptable condition after repair.

Predictive maintenance supplies the necessary information which helps to improve /increase.

1. The production capacity.

2. Product quality.
3. Overall effectiveness of production function.

Benefits of predictive maintenance:

1. Reduced breakdown losses.

2. Reduction of quality defects.
3. Increased net operating profit
4. Reduced maintenance cost.

Condition based Maintenance techniques:

1. Vibration monitoring determines the actual condition f equipments / machines by

studying the noise or vibration produces during functioning.
2. Thermography determines the condition of plant machinery system etc. By studying the
emission of infra red energy i.e., temperature.
3. Tribology determines the dynamic condition of bearing lubrication rotor support
structure of machinery etc. By adapting anyone of the techniques like lubricating oil
analysis, spectgraphic analysis, and ferrography and wear particle analysis.
4. Electrical motor analysis determines the problem within motors and other electrical
equipment.
5. Visual inspection –determines the condition f working elements visually based on the
experience.

Reliability centered maintenance (RCM)

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
 I. When designing, selecting, and installing new systems in a plant.
II. When Setting up preventive maintenance for complex equipment and system fr which are
not clear and how they work.

Total Productive Maintenance[TPM]:

Total productive maintenance is a maintenance program, which involves a newly defined

concept of maintaining plants and equipments. The goal of TPM program is to significantly increase
the production at the same time increasing employee morale and job satisfaction.

TPM Philosophically Resembles TQM in many aspects such as,

I. Requirements of commitment by top level management.

II. Requirement of Empowering Employee to Initiate Corrective action.
III. Accepting long range plan on any on going process.

Implementation of TPM

Stage 1- Initialization

Stage 2- Introduction on TPM

Stage 3- Implementation of TPM

Stage4- Institutionalization

Stage 1

There are five steps

Step1-Annoucement by Management about TPM

Step2- Initial Education

Step3- Setting up TPM departmental committees

Step4- Establishing TPM working system and Target

Step5- A plan for Institutionalizing

Stage 2

Introduction Stage(We care for Quality)

Stage 3
 Implementation Stage:

The following activities which are familiarly called as pillars of TPM are carried out

1. 5’s Principle
2. Autonomous Maintenance(JISHU HOZEN)
3. KAIZEN
4. Planned Maintenance
5. Quality Maintenance
6. Training
7. Office TPM
8. Safety, Health and Environment

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
Autonomous Maintenance JISHU HOZEN

Planned Maintenance

KOBISTU KAIZEN

Pillars 1-5S

a) SEIRI- Sort out

b) SEITON- Organize
c) SEISO- Shine the workplace
d) SEIKETSU- Standardization
e) SHITSUKI- Self discipline

Pillar 2- JISHU HOZEN(Autonomous Maintenance)

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” mean change and “ZEN” means good(for the better). Basically KAIZEN 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/Top Managenemnet Quality circle

Sixteen Major losses in an Organisation

1. Losses that impede Equipment Efficiency

1) Failure losses- Breakdown loss
2) Setup/ adjustment loss
3) Cutting blade loss
4) Start up loss
5) Minor stoppage/ Idling loss
6) Speed loss- operating at low speeds
7) Defect/ Rework loss
8) Scheduled downtime loss
2. Losses that impede Human Work Efficiency
1) Management loss
2) Operating motion loss
3) Line Management loss
4) Logistic loss
5) Measurement and adjustment loss
3. Losses that impede Effective Use of Production Resources
1) Energy loss
2) Die, Jig and total breakage loss
3) Yield Loss

Pillar 4- Planned Maintenance(PM)

Pillar5- Quality Maintenance(QM)

Pillar6- Training

Policy:

1) Focus on Improvement of knowledge, skills and techniques.

2) Creating a training environment for self learning based on few needs
 3) Training curriculum/ Tools/ Assessment , etc.. conductive to employee
revitalization.
4) Training to remove employee fatigue and make work enjoyable

Pillar 7- OFFICE TPM:

Office TPM addresses 12 major losses. They are

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

Office TPM and its Benefits

1) Involvement of all people in support function for focussing on better plant

performance.
2) Better utilized work area
3) Reduce Repetitive work
4) Reduce Inventory level in all parts of the supply chain
5) Reduce administrative cost
6) Reduce inventory carrying cost
7) Reduction in number of files
8) Reduction of overhead cost
9) Productivity of people in support functions
10) Reduction in breakdown of office equipment
11) Reduction of customer complaint due to logistics
12) Reduce manpower
13) Clean and pleasant work environment

PQCDSM in Office TPM:

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

D= Logistics losses(Delay in loading/ unloading)

S= Safety in Material Handling

M= Number of Kaizens in office areas

Pillar 8- Safety, Health and Environment

This pillars aims at achieving

1) Zero Accident
2) Zero Health damage
3) Zero fires

Various Stake Holders of Maintenance Scheduling

planner
operator
schedules

Stakeholders of Maintenance scheduling

Operation superindentent Maintenance supervisors

Storage incharge craftsman

Maintenance Scheduling Principles

Schedules are Important Job

*Plans with Lowest priorities are Important
Schedule from forecast or
Required Skil level highest skill available
*Identify skills One week
*Person workhour Xconsider multiple job on
duration Maintenance
scheduling principles same system
Consider proactive work

Crew leader handles current

Measures performance days work
by analysis of schedule Daily schedule
compilance Assign schedule
Assign name to tasks Schedule for evry work hour
Coordination of resource and available
clearence
emergencies
Repair

Generally the Maintenance Scheduling embraces the following activities,

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

1) Reduce oxidation and rust formation

2) Provide insulation in transformer application
 3) Transmit Mechanical power in hydro fluid power system
4) Seal against dust, dirt and water

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=

Where R is less then or equal to 1 for boundary lubrication

R is in between 5 and less than or equal to 100 for fluid film lubrication

R is between 1 and 5 for mixed lubrication