UNIVA

Universidad Catlica

INDUSTRIAL ENGINEER
Subject:

MAINTENANCE
215-3
TEACHER:

Pedro Antonio Ponce Castellanos

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Presentation
Evaluation
Rules
Project
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Engineering Maintenance
Management
MAINTENANCE
OBJECTIVE:
Understand and clarify the maintenance
concept.

A Maintenance definitions
What is Maintenance?
Maintenance, in terms of this century,
means keeping equipment running or
restoring it to operating condition.

Maintenance is not about fixing things that

break. Maintenance is about preserving,
protecting, safeguarding, and looking after the
very machines that make business possible.

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What is the mission of

maintenance?
The mission of the maintenance
department is to provide excellent
support for customers by reducing
and eventually eliminating the need
for maintenance services.

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What exactly is the purpose of

the maintenance function?

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Maintenance in History

Since the beginning of time, men have always felt the need for the maintenance of
their equipment, even his most rudimentary tools. Most of the failures experienced
have been a result of abuse, as it sometimes still happens.

First, they would only do maintenance when it was no longer possible to run it.

That was called Breakdown or Reactive Maintenance.

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Maintenance in History
It was until 1950 that some groups of Japanese engineers
started a new concept in maintenance that consisted on
following the manufacturers recommendations about the
care that should be taken in the operation and
maintenance of the machines and devices.
That new trend was called Preventive Maintenance.

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Maintenance in History
The times and needs changed, in 1960 new concepts were
established, Productive Maintenance was the name for the
new trend which determined a more professional approach.
The assignment of a higher responsibility to all the people
related to maintenance consisted of a series of
considerations about the reliability and design of the
equipment and the plant itself. The change was so profound
that the term Maintenance was changed to Plant
Engineering and the tasks to be performed included a
higher understanding of the reliability of each element of the
machines and installations in general.
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Maintenance in History
Just a decade later, the globalization of the marketplace
created new, stronger needs for excellence in all activities.
The World-Class standards In terms of equipment
maintenance were understood, a dynamic system was
created. TPM, is a continuous improvement concept that
has proven to be effective, first in Japan and now back in
America (where the concept was first created). It is about
the involvement and participation of each and every one of
the members in the organization towards optimizing the
outcome of each piece of equipment.
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Maintenance in History

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Maintenance Organization
OBJECTIVE:
Understand the place of maintenance organization.
Identify what is the organization roll?
Responsibility and Cost involved with organization .

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Maintenance Organization
Components in maintenance organization:
Resources: people, spares and tools
(composition, location and movement)
Administration: a system of authority and
responsibility for deciding what, when and
how work should be carried out.
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Maintenance Organization
Work planning and control system: a
mechanism for planning and
scheduling the work and feeding
back the information which is
needed if the maintenance effort is
to be correctly directed towards its
defined objective.
Organization is basically concerned
with matching resources and
workload
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Maintenance Organization
The maintenance organization in any
industry or business is faced with the same
problems confronting manufacturing
management in the production of a
competitively priced product.

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Maintenance Organization
Components in maintenance
organization
Resources: People, spares and tools.
Administration: a system of authority and

responsibility for deciding what, when and how

work should be carried out.

Work planning and control system: a

mechanism for planning and scheduling the work

and feeding back the information which is needed
if maintenance effort is to be correctly directed
towards it is defined objective.
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Maintenance Organization
Historically the typical size of a plant
maintenance group in a manufacturing
organization ranged from 5 to 10 % of
the operating force.
Note that we have said the proportional
size of the maintenance effort will
continue to increase but not necessary
the size of the maintenance organization.
Experience has proven that giving
workers more flexibility and authority is
the long term solution to vast majority of
production problems.
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Maintenance Organization
Cost Considerations
Contrary to the opinion of many managers
maintenance costs are highly controllable.
This is because.
For the most part maintenance is subjective. A great
deal of maintenance or a minimal amount of
maintenance can be performed with out ceasing to
operate.
Maintenance work is highly labor intensive and
operations that are labor intensive can be controlled.
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Maintenance Organization
There are four fundamental costs
associated with maintenance
work. These are:
Direct costs: are those costs required to
keep equipment operable. This include
periodic inspection and preventive
maintenance, servicing costs, repair costs,
and overhaul costs.

Standby costs: the total costs of

operating and maintaining standby

equipment needed to be put in operation
when a primary facilities are either under
going a maintenance activity or are
inoperable for some reason.
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Maintenance Organization
There are four fundamental costs
associated with maintenance work.
These are:
Lost production costs: costs due to lost
production because the primary equipment is
down and no standby equipment is available.

Degradation costs: those costs occurring

in deterioration in life span of equipment
resulting from inadequate and/or inferior
maintenance.

Controlling direct maintenance costs will

permit reasonable control of the four
fundamental costs that are related to
maintenance work.
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Maintenance Organization
The responsibility of maintenance.
It is the principal responsibility of maintenance
to provide a service to the operation that
enhances it is ability to make profit.
These include providing a safe environment for
all employees. A safe environment inevitably is
a productive environment.
Maximize the availability of production
processes and equipment throughout the plant.
Conserve energy usage.
Conserve and control the use of spare parts and
maintenance materials.
Perform all maintenance activities when needed,
utilizing qualified employees that perform in an
efficient manner.

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INTEGRATED
MAINTENANCE MATERIALS

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Maintenance Organization
Integrated Maintenance
System

Production availability
Labor effectiveness
Control of materials
Usage of energy
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Maintenance Organization
The place of maintenance in
the plant organization.
The place of maintenance in the
plant organization will vary
with the size complexity, and
product or products produced.

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Maintenance Organization
The maintenance organization.
The structure of the maintenance
organization depends upon both the
size and the product of the
enterprise.
Perhaps the first consideration in
planning a maintenance organization
is the determination of whether to
have centralized or decentralized
maintenance.
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