maintenance genesis presentation
TRANSCRIPT
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Group 2- Members
1. Richa KH2009SMBA18P038
2. Venkatesh KH2009SMBA18P054
3. Diptesh KH2009SMBA18P0664. Jasmeet KH2009SMBA18P070
5. Ramya KH2009SMBA18P101
6. Ankur KH2009SMBA18P104
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Genesis A beginning or origin of anything
Maintenance It is the work of keeping something in proper
condition
Maintenance Genesis
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Breakdown Consequences
Pr
oduction capacity isr
educedOrders are delayed
Noproduction
Overhead continues
Cost per unit increases
Quality issues
Product may be damaged
Safety issues
Injury to employees
Injury to customers
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GoalofMaintenance
To keep production systems in good workingcondition at minimal cost
To ensure maximum availability of the operation
Reasons for maintenance
To avoid production or service disruptions
To not add production or service costsTo maintain high quality
To avoid missed delivery dates
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Availability
ReliabilityProbability that the item will not fail
MaintainabilityThe probability that the item is successfully restored
after failure
Availability
Probability that a system is not failed or undergoing a
repair action when it needs to be used
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Maintenance Management Prior to World War II
Reactive MaintenanceBreakdown maintenance
Reactive approach
Dealing with breakdowns or problems whenthey occur
Challenges :
Poor planning
Incomplete repair
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Maintenance Management Post World War II
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Preventive MaintenanceTo prevent the failure of equipment before it actually
occurs through:
Periodic maintenance ( Time based maintenance -
TBM)
Predictive maintenance
Year - 1950
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Time basedmaintenance (TBM)
Servicing and cleaning equipment
Inspection
Oiling
Replacing parts
Periodic maintenance
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Service life of important part is predicted based on :Inspection
Diagnosis
Parts are used to the limit of
their service life.
It involves condition based maintenance.
Measures and analyze data about deterioration.
Monitor conditions through on-line system.
Predictive maintenance
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Toassess machinery condition it uses:
Non destructive testing techniques
Visual inspection
Performance data
Ultimate Goal ofCBM:Eliminate routine maintenance
Service equipment only when monitoring system
indicates
Key components of CBM:
Vibration monitoring
Thermography
Oil analysis
Condition Based Maintenance (CBM)
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Monitors frequencies to predict impending defect
Compares the vibration spectra of new equipment vs.
subject equipment
Vibration monitoring
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Analysis of thermal information by using non contact
thermal imaging devices.
Thermography
Worn refractory insulation causing hotspot
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Detecting the presence of contamination in oil.
Example:
Electrical transformers oil analyzed for thepresence of carbon deposits
Analyzing High Engine Oil consumption
Oil Analysis
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Improved system reliability.Decreased cost of replacement.
Decreased system downtime.
Better spares inventory management.
Benefits of preventive maintenance
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Condition 1:
The component in question has an increasing failure rate.
Condition 2:
The overall cost of the preventive maintenance action
must be less than the overall cost of a corrective action
When Does Preventive Maintenance Make Sense
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Quick Recap
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Equipment with design weakness must be redesigned toimprove:
Reliability
Maintainability
Preventive Maintenance
Analyzing techniques:
FMEA
Root cause analysis
1957 - Corrective Maintenance
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A methodology to analyze and discover:
All potential failure modes of a system
The effects these failures have on the system
How to correct and or mitigate the failures or effects
on the system.
Failure Mode andEffects Analysis
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Poka-yoke - Eliminates defects
By preventing or correcting mistakes as early as possible.
Applied in processes potential of inducing catastrophic in-
service failures.
Year - 1960
I have an extra
part. I must
have omitted a
step!
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It indicates the design of a new equipment.
Weakness of current machines are sufficiently studied and
incorporated before commissioning a new equipment.
Prevents Maintenance
Improves Availability
Example:
-Using powder metallurgy built porous bronze bearing for
ceiling fans
- Improved automobile batteries
1960 - Maintenance prevention
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Preventive
maintenance
+
Maintenance prevention = Productive maintenance
+
Maintainability Improvement
Maximize plant and equipment effectiveness
Achieve optimum life cycle cost of
production equipment.
1963 - Productive Maintenance
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1971 - Total Productive Maintenance
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Adoption of life cycle approach ,improving the overall performance
of production equipment.
Improving productivity by highly motivated workers ,achieved by
job enlargement.
The use ofvoluntary small group activities for identifying the cause
of failure, possible plant and equipment modifications.
Motives ofTPM
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The concept of "I (Production operators) Operate, You
( Maintenance department ) fix" is not followed.
Uniqueness ofTPM
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Zero Defects Zero Breakdown
Zero accidents
Involve people in all levels of organization.
TPM Objectives
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Obtain Minimum 80% OPE
Obtain Minimum 90% OEE
Rectify customer complaints.
Reduce the manufacturing cost by 30%.
Satisfy the customers needs by 100 %
Reduce accidents.
Follow pollution control measures.
Direct benefits ofTPM
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Higher confidence level among the employees.
Keep the work place clean, neat and attractive.
Favorable change in the attitude of the operators.
Achieve goals by working as team.
Horizontal deployment of a new concept in all areas of the
organization.
Share knowledge and experience.
The workers get a feeling of owning the
machine.
Indirect benefits ofTPM
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Bath Tub Curve
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1975 - Life DataAnalysis (WeibullAnalysis)
Leading method in the world for fitting life data.The three-parameter Weibulls expression is given by:
Where,
= scale parameter,
= shape parameter (or slope),
= location parameter.
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WeibullAnalysis Advantages
Provides reasonably accurate failure analysis andfailure forecasts with extremely small samples.
Provides a simple and useful graphical plot of the
failure data.
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< 1
Implies infant mortality
= 1
Implies failures are
random
An oldpart is as goodas
a newpar
t1 3
Implies rapidwearout in
oldage
Occurs for:
Wear-through
Weibull Interpretation
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Maintenance in IT Environment
IT
System Maintenance shall be performed for thefollowing reasons:
To correct errors
To keep system current
To improve the system
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Why Software/Hardware Maintenance ?
To provide continuity of service
To support mandatory upgrades
To support user requests for improvements
To facilitate future maintenance works
Data Backup
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Maintenance Decision Diagram
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Maintenance Strategy Model
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Challenges facing Modern Maintenance
Selection of most appropriate techniques
Dealing with each type of failure process
Fulfilling the expectations of the owners and users
Cost-effective & enduring maintenance
Involvement & active participation of
all persons concerned and connected
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Changing maintenance techniques at present
Condition monitoring of equipment developed
Machines design based on reliability and maintainability
Hazard studies carried out
Small fast computers & systems came into existence
Failure mode and effects analysis (FMEA) developed
Multi-skilling & team work became the goal and practice
Need based training program e.g. Industrial basic
training, TPM, TQM, Quality circle, 5-S became popular
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Management ofMaintenance
Monitor the work progress daily, weekly or monthly
Identify any significant variance in following through
exception reporting.
Labor hours
Work order costs
Total maintenance cost asset
Develop alternative solutions or actions to reduce
time and costs.
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THANK YOU !