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Session 1
Maintenance Management
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What is Maintenance?
Busy in fire fighting breakdowns rather
than preventing/eliminating the same.
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A maintenance system of today includes
aspects as follows
1. Pr otecting the buildings, str uctur es and plants
2. Incr easing equipment availability and r educing
downtimes; also helping in incr ease utilization of
equipments
3. Contr olling and dir ecting labour for ces.
4. Economy in maintenance depar tment.
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5. Maximizing utilization of available r esour ces.
6. Ensur ing safety of installations and also
r educing envir onmental pollution.
7. R ecor ding expenditur e and costing of
individual jobs and of depar tment/section.
8. Pr epar ing maintenance budgets.
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9.Pr eventing waste of tools, spar es and other
mater ials.
10.Emphasis on waste r ecover y.
11.Impr oving technical communications.
12.Measur ing plant per for mance as a guide for
futur e actions.13.Tr aining of maintenance per sonnel on r elated
topics.
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M aintenance Objectives
( i) To maintain plant and equipments at its maximum
oper ating efficiency, ensur ing oper ational safety
and r educing downtime.
( ii) To safeguar d investments by minimizing r ate of
deter ior ation and achieving this at optimum cost
thr ough budgeting and contr ol.
The maintenance objectives of a big industrial plant
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( iii) To help management in taking decisions on
r eplacements or new investments and actively
par ticipate in specification pr epar ation,
equipment selection, its er ection and
commissioning etc.
( iv) Development of r esour ces for equipments and
spar es and pr oviding technical help for
Vendor's / equipment supplier's selection /
r ating and impor t substitution.
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( v) Help in implementation of suitable pr ocedur es
for pr ocur ement, stor age and consumption of
spar es, tools and consumables etc.
( vi) Standar dization of spar es and consumables in
confor mity with plant, national and
inter national standar ds and help in adoption of
these standar ds by all user s in the plant. Also
help in var iety r eduction and inventor y contr ol.
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( vii) R unning of centr alized ser vices like Steam
Gener ation, water supply, air supply and fuel
supply etc.
( viii) R unning of Captive Wor kshops for r epair and
r econditioning and also making some new
spar es.
( ix) Help in tr aining and development of skilled
wor kmen and executives.
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Maintenance is an age-old function which
developed and pr ogr essed, knowingly or
unknowingly, along with the oper ation of
equipments. In ear ly ages, maintenance was,
pr obably, not a separ ate identity but the job of
maintenance was consider ed as par t and
par cel of-oper ator's job. This was possible
because of simplicity and openness of
machines and equipments.
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In sewing machine, tailor used to lubr icate the
machine, thus, even the lubr ication job, which is
basically a maintenance job, was done by the
same per sonnel without giving the job a separ ate
identity. However , with the gr owth of
industr ialisation, the complexity of the machines
(mechanical, electr ical and electr onics together)
incr eased and the machines became less simple
and less open.
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This star ted cr eating pr oblems for the oper ating
per sonnel and the concept of maintenance as asepar ate discipline and separ ate identity star ted.
Maintenance Pr evention (MP) was pr obably fir st
known in 1960s f r om a factor y Magazine in
United States and that said that Maintenance
Pr evention (MP) meant design, manufactur e or
pur chase of equipment which is f r ee f r om
maintenance.
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Inflated and incr eased down time cost called for the
well managed maintenance pr ogr ams, to enhance
the life of existing equipments and components,
became the essential aspects of all management
str ategies.
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It consists of specialists hence is a
knowledge house of the or ganization. The
specialization is pr edominantly achieved
thr ough hands-on exper ience over a per iod
of year s. Most of such specialists ar e
pr actice or iented and had limited academic
exposur e.
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'Maintenance can be defined as a set of
activities that ensur e any physical asset
to continue to fulfill its intended
functions to the standar d of
per for mance desir ed by the user'
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The activities in maintenance
commences r ight f r om design of the
equipment and culminates in
scr apping it, which means
maintenance is associated with
ever y par t of the equipment's entir e
lifecycle.
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Maintenance doesn't limit its scope
to machiner ies as commonly
misunder stood, but includes land &
buildings, auxiliar y equipments,
safety equipments and office
equipments. In shor t maintenance
encompasses all the physical assets
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The r ight maintenance is the one that
will ensur e per for mance of equipment
with highest possible efficiency
desir ed by the user
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The efficiency level is decided by the
user because it is connected to the cost.
Efficiency doesn't come f r ee. Ever yinitiative demands cer tain cost or
compr omise and the user has to
balance it for an over all benefit
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Maintenance Engineer ing/Maintenance
Management is the most impor tant
component of Plant Engineer ing and
Plant Engineer ing is pr obably the
biggest for ce to incr ease pr oductivity .
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'Maintenance is an investment that
buys / gives mor e pr oduction time.
(example health of a per son)
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Also we cannot cope up with today's jobs and
pr oblems with yester day's tools and techniques.
We have to use tools and techniques of today,
compatible with today's pr oblems and also with
the anticipated pr oblems of tomorr ow (near
futur e). Educational and r esear ch institutionsshould cooper ate with industr ies to ease out the
pr oblems.
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If all these ar e not taken car e of, a
maintenance man would be so busy in
committing suicides that he would
har dly have any time to live i.e., he
would be busy in fir e fighting
br eakdowns r ather than pr eventing/
eliminating the same.
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Q1.What is Maintenance ? State differ ent aspects
of Maintenance In today¶s wor ldQ2.What ar e differ ent Maintenance objectives
Q3.Why is it impor tant to know the stage of
pr oduct life cycle in which an equipment is in
the context of Maintenance
Q4.What is the r ole of Maintenance in
Manufactur ing?
Q5.How Maintenance per sonnel ar e r esponsiblefor pr ofit making and efficient r unning of
business in any or ganization?