Manufacturing & Operations Management

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Maintenance Management

Introduction
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A plant is a place where men, materials, money, equipment, machinery, etc. are brought together for manufacturing products Quality of product depends on the performance of equipment & machinery Breakdown of one equipment may paralyze the whole system and the loss of production hour may increase the wound

Introduction Continued
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All the production facilities are subject to deterioration (temperature rise, vibrations, loosening, seasoning of parts, accumulation of dirt, rusting of parts, etc.) due to their use and exposure to the environmental conditions If unchecked and unattended, culminates and brings facilities useless In this context, maintenance assumes importance as an engineering function

What is maintenance management ?

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Maintenance management is systematic approach

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to planning the maintenance activities, use of decision making tools to evaluate & select the best set of alternatives for maintenance, cost & operational control Improving the overall efficiency & effectiveness of the operating system

Objectives of Maintenance

To keep all the production facilities in an optimum working condition Ensure specified accuracy to products & time schedule of delivery to customers To keep the downtime of the machine at minimum To improve productivity of existing machine tools and to avoid sinking of additional capital To keep the factory overheads to minimum

To extend the useful life of plant and machinery, without sacrificing the level of performance Minimization of wear and tear to increase the longevity of the equipment Elimination of unsafe conditions that cause accidents thereby ensuring safety of the workmen Achievement of all the above objectives at the least cost to the company

Costs associated with breakdown

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Down time cost Idle wages Loss of materials Cost of repairs Opportunity cost Effect on other machines Expediting cost Accident cost Added set up cost Tool breakage Increase in WIP investment

Costs Continued

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Overtime wages paid to the maintenance Premium paid on the spare parts Reduced life of the equipment Broken promises Lowered Morale Higher spares inventory investment Cost of standby equipment

Economic aspects of maintenance

Total Cost Cost Total Costs of Repairs Cost of labour & overhead Cost of quality Cost of downtime low Degree of maintenance efforts high

Types of maintenance
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Breakdown maintenance: In this type of maintenance, no care is taken for the machine, until equipment fails. Repair is then undertaken. This type of maintenance could be used when the equipment failure does not significantly affect the operation or production or generate any significant loss other than repair cost. However, an important aspect is that the failure of a component from a big machine may be injurious to the operator. Hence breakdown maintenance should be avoided.

Preventive maintenance
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It is a regular maintenance (cleaning, inspection, oiling and re-tightening), design to retain the healthy condition of equipment and prevent failure through the prevention of deterioration, periodic inspection or equipment condition diagnosis, to measure deterioration. It is further divided into periodic maintenance and predictive maintenance. Just like human life is extended by preventive medicine, the equipment service life can be prolonged by doing preventive maintenance.

Basic activities of the preventive maintenance

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Preventive inspection Planned lubrication Cleaning and upkeep Minor adjustments and repairs Equipment records Spares control Condition monitoring

Periodic maintenance (Time based maintenance - TBM)

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Time based maintenance consists of periodically inspecting, servicing and cleaning equipment and replacing parts to prevent sudden failure and process problems. E.g. Replacement of coolant or oil every 15 days.

Predictive maintenance:
This is a method in which the service life of important part is predicted based on inspection or diagnosis, in order to use the parts to the limit of their service life. Compared to periodic maintenance, predictive maintenance is condition-based maintenance. It manages trend values, by measuring and analyzing data about deterioration and employs a surveillance system, designed to monitor conditions through an on-line system. E.g. Replacement of coolant or oil, if there is a change in color. Change in color indicates the deteriorating condition of the oil. As this is a condition-based maintenance, the oil or coolant is replaced.

Corrective maintenance
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It improves equipment and its components so that preventive maintenance can be carried out reliably. Equipment with design weakness must be redesigned to improve reliability or improving maintainability. This happens at the equipment user level. E.g. Installing a guard, to prevent the burrs falling in the coolant tank

Maintenance prevention
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This program indicates the design of new equipment. Weakness of current machines is sufficiently studied (on site information leading to failure prevention, easier maintenance and prevents of defects, safety and ease of manufacturing). The observations and the study made are shared with the equipment manufacturer and necessary changes are made in the design of new machine.

Planning Maintenance work cycle

Planning

Controlling

Maintenance Planning

Scheduling

Analysis

Executing

Recording

Total Productive Maintenance

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Development of the TPM concept began in 1970s in Japan JIPM (Japan Institute of Plant Maintenance) Award is given to best TPM implementation

Concept
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The word TOTAL in TPM has three meaning n Total Effectiveness : Indicates TPM pursuit of economic efficiency or profitability n Total Maintenance System : includes maintenance prevention (MP) and maintainability improvement (MI) as well as preventive maintenance n Total Participation of all Employees : includes Autonomous maintenance by operators through SGA

Objectives
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The objective of TPM is much wider then just minimizing equipment; the objective is to minimize the life cycle cost i.e., the cost for the entire lifespan of the equipment. TPM aims to maximize equipment effectiveness TPM establishes a thorough system of preventive maintenance for the entire life span TPM is implemented by various departments (Engineering, operations, maintenance) TPM involves every single employee TPM is based on promotion of PM through motivation management (autonomous SGA)

TPM aims for

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Zero Defects (ZD) Zero Accidents Zero Breakdowns In TPM ZERO is HERO

Stages in TPM implementation:

Step A - PREPARATORY STAGE: o STEP 1 - Announcement by Management to all about TPM introduction in the organization: o STEP 2 - Initial education and propaganda for TPM o STEP 3 - Setting up TPM and departmental committees o STEP 4 - Establishing the TPM working system and target: (benchmarking & target)

Stages in TPM implementation:

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STEP B - INTRODUCTION STAGE

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Small get-together with suppliers and customers.

STAGE C - IMPLEMENTATION

STAGE D - INSTITUTIONALISING STAGE

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By now the TPM implementation activities would have reached maturity stage. Now is the time to apply for various award & accolades.

Direct benefits of TPM

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Increase in productivity and OEE (Overall Equipment Efficiency) Reduction in customer complaints. Reduction in the manufacturing cost by 30%. Satisfying the customers needs by 100 % (Delivering the right quantity at the right time, in the required quality.) Reduced accidents.

Indirect benefits of TPM

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Higher confidence level among the employees. A clean, neat and attractive work place. 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. Sharing knowledge and experience. The workers get a feeling of owning the machine.

The requirements for TPM to succeed are:

Commitment from Management - initial drive from top down

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Commitment from shop floor - Bottom up driven after start

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The necessary resources made available Support from Maintenance Departments Everybody to try it.

CONCLUSION
Typically 60% of breakdowns are caused by loose bolts and poor lubrication

Dirty conditions are a major cause of failure and accelerate wear and deterioration of machinery

Product quality, throughput, safety and morale are all inextricably linked to the machine condition