DP 471: ELECTRICAL SAFETY AND MAINTENANCE

LESSON 1
1. Introduction to Maintenance Management
Why do we study maintenance?
The management of maintenance is gaining importance as one of the key factors in increasing
the productivity of a company. The maintenance has so discernible influence on the quality of
production processes that production industries can no longer function without maintenance.
And the quality of the production process has a direct influence on the quality of the products
and the costs of production. Besides, it is also to be noted that maintenance influences the
availability of the equipment, which influences the production's conformity to the production
schedule. Therefore reasons for studying maintenance can be divided into the following groups:
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quality of products - Companies are incurring heavy loses resulting from sub-standard
products due to defective machinery. These products have to be recycled or thrown out as
scraps. To avoid such kind of costs, maintenance of equipment needs to be emphasised.
reliability of production system - reliability of production system depends on the availability
of the installed machinery and equipment.
economical aspects - the cost of not doing proper maintenance is too huge. Therefore to
avoid such costs, managers should understand the importance of carrying out proper
maintenance.
organisational aspects - proper co-ordination of maintenance and production workorders
so as to avoid conflicts in these two departments.
safety matters - Most of the industrial accidents occur due to defective equipment. When
an accident takes place there is a danger of polluting the environment, operator injury or
even destruction of the equipment.

What is the cost of Maintenance?

Let us view some countries, which keep records on their statistics: Manufacturing industries in
the United States spend more than 200 billion dollars each year on maintenance, and the costs
of maintenance represent between 15% and 40% of the costs of good produced depending on
the type of industry. In the Federal Republic of Germany 10% of GNP (Gross National Product),
each year is used as the maintenance expenditures, which represented about 226 billion DM for
the maintenance expenditures in the year 1989. (What about Tanzania? How much does
Tanzania spend on the maintenance?) From this economic point of view, it is obvious that the
maintenance departments contain a high potential of reducing the costs of production and
increasing the profitability of the company.

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Basic Definitions for Terms used in Maintenance:

1.1 maintenance
Literal definition - Literal definition of maintenance means: to cause to continue in a specific
state, relation or position ... or to keep in good order or ... the preservation as nearly
as possible of the originally designed and constructed condition of an object for
purposes of prolonging the life span of the object.
From economist perception, maintenance is largely an operational activity located at the shop
floor level of production facility. Looked at from this perspective, issues of maintenance have
been seen by conventional economists as matters of:
a) simply oiling and lubricating plant equipment and machinery, rehabilitating road
infrastructure, building and so forth;
b) tightening of bearings, bolts and nuts of equipment and machinery when they loosen or are
replace; and
c) replacing and fixing a broken and damaged part or component of equipment, machinery,
etc..
According to British Standard BS 3811:1964 maintenance is defined as work undertaken in
order to keep or restore every facility, i.e. every part of a site, building and contents, to an
acceptable standard. (NOTE 1. Where there are statutory requirements for maintenance the
acceptable standard to be reached must be not less than that necessary to meet such
requirements. 2. 'Maintained' is defined in the Factories Act, 1961 as: Maintained in an efficient
state, in efficient working order and in good repair).
According to the German Institute for Standardisation DIN 31051 maintenance is defined as
"actions for preservation and restoration of the nominal-condition of a technical

system as well as for substantiating and assessing the real-condition of the

technical system".
The functional division of the industrial maintenance management can be viewed in four main
categories (see Figure 1.1):
a) Maintenance work planning;
b) Maintenance programming;
c) Maintenance controlling; and
d) Maintenance analysis.
1.1.1 maintenance work planning
According to British Standard maintenance planning is defined as the deciding in advance the
jobs, methods, materials, tools, machines, labour, timing and time required for the carrying out of maintenance. The maintenance work planning deals with the planning of the maintenance strategies, the planning of the maintenance personnel capacity requirement, the budgeting for the maintenance, the planning for the maintenance material and the consultation of the
other related departments. The activities of maintenance work planning include the following:
- maintenance strategy planning
- personnel planning
- planning of maintenance equipment
- maintenance materials planning

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- budgeting for maintenance

- creation of maintenance workorders
- maintenance cost planning

Maintenance
management

Maintenance
work planning

Maintenance
programming

Maintenance
controlling

Maintenance
analysis

Maintenance
strategy planning

Maintenance
programm

Releasing of
workorders

Analysis of
deviations

Personnel
planning

Maintenance
schedule and
capacity

Monitoring of
workorders

Analysis of
weak points

Material
planning

Maintenance
procurements

Budgeting

Consultation

Figure 1.1 Functional Division of Industrial Maintenance

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1.1.2 maintenance programming

Maintenance Program is defined as a list allocating specific maintenance task to a specific
period. Maintenance programming is defines as the preparation of a maintenance programme.
Maintenance programming is mainly concerned with the establishment of the maintenance
schedules and capacity, and the planning for the procurement of the maintenance material.
From the description of these two functions of the maintenance, it is obvious that, there is no
strict demarcation between maintenance work planning and maintenance programming. In the
maintenance programming the following tasks of performed
- planning of maintenance programmes
- maintenance capacity planning
- planning for maintenance schedules
- quantity planning
1.1.3 maintenance controlling
Maintenance controlling deals with the releasing and monitoring of the maintenance workorders. It is the maintenance controlling that scrutinises the availability of the equipment, harmonises the distribution of the maintenance tasks, monitors the available capacity and collects the
data concerning the workorders. Therefore the main tasks of maintenance controlling include
releasing of maintenance workorders and supervision of the execution of the maintenance
workorders.
1.1.4 maintenance analysis
Maintenance analysis deals with the identification and analysis of the equipment weak points,
and the analysis of the deviations in the carrying out of the maintenance workorders. The
maintenance analysis is based on the results obtained from the monitoring of the maintenance
workorders. The maintenance analysis is more appropriate in the practise for the purpose of
rectifying the identified weak points

1.2 Maintenance related terms

The following definitions are according to British Standard 3811:1964 and DIN 31051 and they
are arranged in alphabetical order rather than relationship order.
1.2.1 Availability
Availability is the period during which a facility is in a usable condition. Availability can be
defined as the proportion of time during which a piece of equipment is in operational or able to
run if required. Total time, in this case, is the time during which the equipment was expected to
be running.
Total time - (Scheduled & Unscheduled downtime)
AVAILABILITY = _____________________________________________
Total time

Availability factor is the ratio of Availability to the period of maximum requirement.

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Operational availability is defined here as the probability that a piece of equipment, when used
in actual operational environment under specified conditions will operate (i.e. do its job)
satisfactorily when called upon. It is usually indicated by the proportion of official time during
which the equipment is in operational or able to operate condition. By official time it is meant the
time during which the equipment is expected to be in running condition (for production or other
business functions).
1.2.2 Breakdown maintenance (This means planned Corrective Breakdown maintenance.)
Breakdown maintenance is a work that is carried out after a failure, but for which advance
provision has been made in the form of spares, materials, labour and equipment. (cf. definitions
for Repair Maintenance, Corrective Maintenance, Unscheduled Maintenance, Unplanned
maintenance, and Emergency Maintenance).
1.2.3 Check
Check in this context is defined as to compare with an acceptable standard by suitable or
defined means, whilst the facility is non-operational.
1.2.4 Clean
The term Clean in maintenance is defined as to reduce contamination to an acceptable standard
1.2.5 Condition Based Maintenance (Predictive Maintenance)
This is a special type of preventive maintenance in which a continuous monitoring of the
condition of the equipment is done and maintenance is done only when necessary. This also
can be performed in either a running or shutdown condition.
1.2.6 Corrective maintenance (This means planned corrective maintenance.)
Corrective maintenance can be defined as work undertaken to restore a facility to an acceptable standard.
1.2.7 Downtime
Period during which a facility is not ready for use
1.2.8 Emergency maintenance (This means unplanned emergency maintenance.)
Emergency maintenance is the work necessitated by unforeseen breakdowns or damage.
1.2.9 Facility register
A record of facilities including information such as constructional and technical details about
each piece of equipment. This may be combined with an inventory

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1.2.10 Failure
Mechanical failure refers to inability of a component or part of a piece of equipment to perform it
designed function. Failure occurs at a point where stress toward which a part is subjected to
exceeds the strength of the part at that time.
1.2.11 Failure Rate
Failure rate is defined as the number of failures per period of time during which failure can
occur. Failure rate is normally presented in terms of failures per hour or other multiples of hour.
Failure rate can also be presented in terms of the number of operations or number of cycles.
1.2.12 Fault report
Fault report is a document reporting deviation of a facility from an acceptable standard.
1.2.13 History card
History card is a document on which information about all work done on and/or by a particular
facility is recorded.
1.2.14 Inspection
Inspection in this context will be defined by DIN 31051 as "actions for substantiating and assessing the real-condition of the technical system". Inspection activities verify the level of wear
and tear of a technical system. According to BS Inspection is the process of ensuring by assessment that a facility reaches the necessary standard of quality or performance and that the
level is maintained.
1.2.15 Inventory
Inventory is a list of all facilities, i.e. all parts of a site, building and contents, for purposes of
identification.
1.2.16 Job interval
Job interval is the period, which may be based on time or other factors, between occurrences of
a particular maintenance job
1.2.17 Job report
Job report is a statement recording the work done and the condition of the facility
1.2.18 Job card
Job card is a document requesting the maintenance work to be done
1.2.19 Job specification
Job specification is a document describing the maintenance work to be done

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1.2.20 Maintainability
Maintainability can be defined as the inherent characteristic of a design or installation that
determines the ease, economy, safety, and accuracy with which maintenance actions can be
performed.
1.2.21 Maintenance management
Maintenance management is the organization of maintenance within an agreed policy
1.2.22 Maintenance Prevention (Design-out Maintenance, Renovate Maintenance,
Improvement Maintenance)
Design or redesign of the equipment or part of the equipment for minimal or, ideally, no maintenance. The re-design of the equipment or part of the equipment can take place either while the
equipment is running or is shutdown
1.2.23 Maintenance schedule
Maintenance schedule is a comprehensive list of maintenance tasks and their incidence
1.2.24 Maintenance strategy
Maintenance strategy planning can be defined as a principal function of planning, whereby the
type of maintenance, the extent of doing and the time of carrying out of maintenance actions
will be established. The maintenance strategy for each piece of equipment can therefore be
defined as the determination of the maintenance actions for this piece of equipment, the establishment of the time of accomplishing the maintenance actions and the fixing of the type of
maintenance personnel to carry out the maintenance actions.
1.2.25 Overhaul
Overhaul can be defined as a comprehensive examination and restoration of a facility, or a
major part thereof to an acceptable standard (Other terms used include: RECONDITION,
REFIT, and REBUILD)
1.2.26 Permit to work
Permit to work is a signed document, authorizing access to a facility, which must define conditions, including safety precautions, under which work may be carried out. This may include a
document, signed on completion of maintenance, stating that a facility is safe and ready for
use.
1.2.27 Planned maintenance
Planned maintenance is work organized and carried out with forethought, control and records
1.2.28 Preventive maintenance (This means planned preventive maintenance)
Preventive maintenance is a work, which is directed to the prevention of failure of a facility

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1.2.29 Regular Preventive Maintenance

Doing regular maintenance at a pre-planned time interval or production cycles
1.2.30 Reliability
Reliability, in common language, refers to ability to perform a required task satisfactorily without
failure. Mechanical reliability is the probability that a component, device or system will perform
its prescribed duty without failure for a given time when operated correctly in a specified
environment.
1.2.31 Repair
Repair can be defined as "actions for restoration of the nominal-condition of a technical system". Repair includes all maintenance actions aimed at extending the usability of a technical
system after a failure.
1.2.32 Routine maintenance
Routine maintenance is a term used in the context of maintenance tasks of a repetitive and
minor nature. It should not be used, as this type of work is part of that covered by the term
'running maintenance' and 'shut-down maintenance'
1.2.33 Running maintenance (This means planned preventive running maintenance.)
Running maintenance is a work, which can be carried out whilst the facility is in service
1.2.34 Scheduled maintenance
Scheduled maintenance is a term sometimes used to define the fields covered by running
maintenance and shutdown maintenance.
1.2.35 Service
In the context of maintenance, the term service will be defined as "actions for preservation of a
technical system". Service consists of all operative activities aimed at avoiding or reducing the
wear and tear of a maintenance object. Servicing term sometimes is used to describe the act of
carrying out minor planned maintenance
1.2.36 Shutdown maintenance ( planned preventive or corrective shutdown maintenance.)
Shutdown maintenance is a work that can only be carried out when the facility is, or is taken,
out of service
1.2.37 Test
Test is to compare with an acceptable standard by suitable or defined means, whilst the facility
is operational

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1.2.38 Utilization factor

Utilization factor is the ratio of Availability to The period of actual use
1.2.39 Work order
Work order is a written instruction detailing work to be carried out
1.2.40 Work requisition
Work requisition is a document requesting work to be carried out

Maintenance

Planned Maintenance

Preventive
Maintenance

Regular Preventive
Maintenance

Unplanned
Maintenance

Corrective
Maintenance

Condition based
Maintenance

Breakdown
Maintenance

Figure 1.2: Types of Maintenance

1.3 Objectives of Maintenance
The following are the main known maintenance objectives:
a)
to extend the useful life of equipment;
b)
to ensure the optimum availability of installed equipment for production;
c)
to increase reliability of equipment, i.e., to ensure instant readiness of all equipment for
emergence use; and,
d)
to ensure the safety of equipment and personnel.

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In summary the benefits of a good Industrial Maintenance System (IMS) are:

a)
reduction of the overall production costs;
b)
increase of productivity;
c)
increase of the efficiency of the equipment;
d)
based on economical as well as the managerial and organisational aspect of
maintenance (cf. subjective decision making);
e)
better conservation of equipment and increased life expectancy: this will result in less
cash outlays for replacement of plant and equipment;
f)
better quality goods and/or services, since the equipment will be always in good running
condition, thus producing fewer defective products and less scrap; and,
g)
increase of the safety for the workers and improve protection for the plant: this will
result in less insurance and compensation costs.

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