Maintenance Management Chapter One PDF

MAINTENANCE MANAGEMENT Chapter one 2020/2021  1. Introduction In an era of competitive marketplace and ever-changing economics, there are intense pressures on organizations in both the manufacturing and service sectors to respond to customers’ dem...

MAINTENANCE MANAGEMENT Chapter one 2020/2021  1. Introduction In an era of competitive marketplace and ever-changing economics, there are intense pressures on organizations in both the manufacturing and service sectors to respond to customers’ demands and deliver high-quality products in a timely manner. The organizations have to gear their strategies toward agility, quality, automation, and high performance. This has resulted in very high investments in equipment and people. To achieve the targeted rates of return on investment and survive in these dynamic economics, equipment has to be reliable and safe to operate without costly work stoppages and repairs. 1. Introduction  2. Strategic Holistic System Approach Maintenance is defined as the combination of activities by which equipment or a system is kept or restored to a state in which it can perform its designated function. Maintenance is an important factor in product and service quality and can be used as a strategy for successful competition. Maintenance can be considered as a system with a set of processes and activities carried out in parallel with production or service systems  2. Strategic Holistic System Approach A diagrammatic shows the relationship among organizational objectives, production/operation process, and maintenance.  2. Strategic Holistic System Approach A maintenance system can be viewed as an integrated input–output model. The inputs to such a model are labor, management, tools, spares, equipment, etc., and the output is equipment that is up, reliable, and well configured to achieve the planned operation of the plant. A maintenance system activities needed to make this system efficient and effective include planning, designing, organizing, controlling, and improving.  2. Strategic Holistic System Approach Maintenance System  3. Planning Activities Planning activities generally include the following: 1. Strategic systems alliances 2. Maintenance strategies 3. Maintenance load forecasting 4. Maintenance capacity 5. Maintenance organization 6. Maintenance scheduling.  3.1 Strategic Systems Alliance 1. Strategic Systems Alliance Maintenance departments should have their own strategic plans that are aligned with their organizations’ strategic objectives and managed with maximum efficiency and effectiveness taking into consideration the holistic system approach. Maintenance methodology is the strategy to be used at the equipment maintenance level, and the support includes maintenance key processes, manning, information system, training, and performance management and reward system. / Maintenance outsourcing  3.2 Maintenance Strategies 2. Maintenance Strategies The maintenance methodology is derived from the maintenance system objectives that are aligned with the organization’s mission and strategic goals. To implement the methodology, the following strategies can play an effective role if applied in the right way. 1. Breakdown/corrective maintenance 2 Time- or use-based preventive maintenance 3 Condition-based preventive maintenance 4. Opportunity maintenance 5. Fault finding 6. Design modification 7. Overhaul 8. Replacement  3.2 Maintenance Strategies 1. Breakdown/Corrective Maintenance This type of maintenance is only performed when the equipment is incapable of further operation. There is no element of planning for this type of maintenance. This is the case when the extra cost of other types of maintenance cannot be justified. This type of strategy is sometimes referred to as run to failure strategy. It is applicable mostly to electronic components.  3.2 Maintenance Strategies 2. Time- or Use-Based Preventive Maintenance Preventive maintenance (PM) is any planned maintenance performed to counteract potential failures. It could be implemented based on the use or equipment condition. The time- or use-based PM is performed on an hours run or calendar basis. It needs a high level of planning. The specific routines to be carried out are known as well as their frequencies. In determining the frequency, usually knowledge about failure distribution or equipment reliability is needed Water Sector.  3.2 Maintenance Strategies 3. Condition-Based Preventive Maintenance Condition-based maintenance is carried out on the basis of the known condition of the equipment. The condition of the equipment is determined by monitoring key equipment parameters whose values are affected by the condition of the equipment. This strategy is also known as predictive maintenance Communications sector  3.2 Maintenance Strategies 4. Opportunity Maintenance This type of maintenance, as the name implies, is carried out when the opportunity arises. Such opportunities may arise during shutdown periods of a particular system and can be utilized for carrying out known maintenance tasks. 5. Fault Finding Fault finding is an act or inspection performed to assess the level of failure set on. An example of fault finding is checking the spare tire of a car prior to taking a long trip.  3.2 Maintenance Strategies 6. Design Modification Design modification is carried out to bring equipment to a current acceptable condition. It involves improvement and sometimes manufacturing and capacity expansion. It usually requires coordination with engineering and other departments in the organization to do this type of work. 7. Overhaul Overhaul is a comprehensive examination and restoration of equipment or a major of equipment to an acceptable condition. This is usually a major task.  3.2 Maintenance Strategies 8. Replacement This strategy is to replace the equipment instead of performing maintenance. It could be a planned replacement or replacement upon failure 3.2 Maintenance Strategies  3.3 Maintenance Load Forecasting Maintenance load forecasting is the process by which the maintenance load is predicted. The maintenance load in a given plant varies randomly and, among other factors, can be a function of the age of the equipment, the rate of its use, maintenance quality, climatic factors, and skills of maintenance craftsmen. Maintenance load forecasting is essential for achieving a desired level of effectiveness and resource utilization, and without it, many maintenance functions cannot be performed well.  3.3 Maintenance Load Forecasting Maintenance load forecasting and maintenance system.  3.4 Maintenance Capacity Planning Maintenance capacity planning determines the resources needed to meet the demand for maintenance work. Those resources include manpower(craftsmen), material, spare parts, equipment, and required maintenance tools. Since the maintenance load is a random variable, the exact number of various types of craftsmen cannot be determined. Therefore, without reasonably accurate forecasts for the future maintenance work demand, it would not be possible to do proper long-range capacity planning. In order to have better utilization of manpower, organizations tend to reduce the number of available craftsmen than their expected need.  3.5 Maintenance Organization Many factors influence maintenance organization. The factors include plant size, maintenance load, type of organization, and craftsmen skills. Based on these factors and other, maintenance may be organized on departmental, area, or central basis. For Example in large organizations, decentralization of maintenance can produce quicker response time and can allow the craftsmen to become more experienced on the problems of a particular section of the plant. The creation of a number of small units tends to reduce the flexibility of the maintenance system as a whole. The range of skills available becomes reduced, and manpower utilization is usually less than that in a centralized maintenance unit. In some cases, a compromise solution is possible which is called a cascade system. This system enables production area maintenance units to be linked to the central maintenance unit.  3.5 Maintenance Organization Cascade system  3.6 Maintenance Scheduling Maintenance scheduling is the process of assigning resources and manpower to jobs to be accomplished at certain times. It is necessary to ensure that the needed craftsmen, the parts, and the materials required are available before a maintenance task can be scheduled. Maintenance work pertaining to the critical equipment in a plant is treated on a priority basis and is attended to before any other job is undertaken. The effectiveness of a maintenance system is greatly influenced by the maintenance schedule developed and its ability to accommodate changes. A high level of maintenance schedule effectiveness is indicative of a high level of maintenance effectiveness.  4. Organizing and Designing Activities Organizing and designing a maintenance system includes the following: 1. Job design 2. Standards 3. Project management  4. Organizing and Designing Activities Job Design Job design, as related to maintenance work, comprises the work content of each job and determines the method that is to be used, the special tools needed, and the skilled persons required. Time Standards Once the maintenance task goes through the job design stage, it is necessary to estimate the time needed for completing the job. Realistic time standards go a long way in monitoring and increasing effectiveness of craftsmen, thus minimizing the plant downtime. It is not essential to have standards for all the maintenance jobs.  4. Organizing and Designing Activities Project Management Project management comes when planned major overhauls and preventive maintenance services are periodically carried out in most of the large plants. During this period, the entire plant or part of the plant is shut down. It is advantageous to plan and chart the work in order to minimize the downtime and make the best use of resources. Project management involves developing networks of activities and then using techniques such as the critical path method (CPM) or program evaluation and review technique (PERT).  5. Control Activities Control is an essential part of scientific management. Control as applied to a maintenance system includes the following activities: 1. Work control 2. Inventory control 3. Cost control 4. Quality control.  5. Control Activities Work Control The maintenance system is driven by demand for maintenance work. The maintenance work load is greatly influenced by the maintenance strategies. The management and control of the maintenance work is essential for achieving set plans. Inventory Control Inventory control is the technique of maintaining spares and materials at desired levels. It is essential that an optimal level of spares be maintained, which minimizes the cost of holding the item in stock and costs incurred if the spares are not available.  5. Control Activities Cost Control Maintenance cost control is a function of the maintenance philosophy, operation pattern, type of system, and procedures and standards adopted by the organization. Such as the direct maintenance lost production, equipment degradation, backups, and over maintenance costs. The control of maintenance cost optimizes all the costs in maintenance, while achieving set organizational objectives such as availability, “quality rate,” and other efficiency and effectiveness measures. Quality Control Quality control is exercised by measuring the attributes of the product or service and comparing the same with the product or service specifications, respectively. Maintenance can also be viewed as a process, and the quality of its output can be controlled. In the case of maintenance work, “doing it right the first time” is very essential. High quality is usually assured by checking the critical maintenance jobs or by maintenance supervision.  6. Managing for Quality and Training Craftsmen performing substandard maintenance work must be identified. This can be achieved by keeping track of repeat jobs by a given craftsman. Further analysis can be carried out to locate the cause(s) of such substandard work. The likely reasons are non-availability of special tools, craftsman not possessing the needed skill level or poor supervision. Eradicating such causes and monitoring the maintenance work completed can result in improved maintenance production quality.  7. Reliability-Centered Maintenance (RCM) Reliability centred maintenance (RCM) is a corporate-level maintenance strategy that is implemented to optimize the maintenance program of a company. The final result of an RCM program is the implementation of a specific maintenance strategy on each of the assets of the facility. RCM is a high-level strategy that may result in an optimized preventive maintenance (PM) that focuses on system and equipment functions. It has been implemented in several industries that include nuclear, energy, and petrochemical.  8. Total Productive Maintenance (TPM) TPM is an approach to managing maintenance by bringing total quality management (TQM) approaches and techniques to maintenance. TPM depends on equipment management and employee empowerment. The backbone of TPM is an effective preventive maintenance program.  9. Intelligent Maintenance The developments of information and communication technologies provide enablers for intelligent maintenance. These developments made it possible to monitor equipment, transfer data, share information, analyze data with embedded systems, and coordinate activities over the Web.  10. Human Behavior In carrying out the functions of planning, organizing, and controlling, maintenance managers are concerned with how their actions affect human behavior. They should try to know how the behavior of subordinates can affect management’s planning, organizing, and controlling actions. In maintenance decision making, behavior of subordinates should be of interest to management. It should be ensured that the desired level of craftsmen satisfaction is achieved and maintained  11. Maintenance Terms Maintenance management is emerging as a discipline with its own methods, techniques, models, and terms. The definitions are based to a great extent on the British Standard. Maintenance Terms  The End Thank You For Your Attention