MAINTENANCE ENGINEERING
PRINCIPLES AND PRACTICES OF
MAINTENANCE PLANNING MAINTENANCE
Maintenance is the recurring and routine
process .
Industries are in era of global competition.
tools for the engineering analysis Increased For keeping a machine in its normal operating
awareness in use of modern and condition so that it can deliver the expected
sophisticated performance.
One among the area is MAITENANCE To ensure that production equipment are
PLANNING AND MANAGEMENT available for use for maximum time at
minimum cost within stipulated time .
LONG RANGE PLANNING
Planning ensures the smooth operations of It refers to the planning spread over of 5 to 10
the system. years.
For effective working ,it is necessary to plan
and schedule its activities. SHORT RANGE PLANNING
The planning is classified into three categories It is prepared by the concerned departments
i. Long range planning for a relatively shorter period of time say 1 to
ii. Short range planning 2 years.
iii. Planning for immediate activity.
IMMEDIATE ACTIVITY PLANNING • The maintenance planning should be careful
• It is a routine and is done at the working level
designed in such a manner it is able to tackle
as and when required.
the emergency maintenance.
MAINTENANCE PLANNING • OBJECTIVES OF MAINTENANCE
Maintenance planning is the task of organizing
PLANNING
resources to carry out a job satisfaction at a
reasonable cost within a specified period of • The most important objectives of the
time maintenance system is the maximization of
availability of equipments and facilities.
It involves the assignment of jobs to the
maintenance crew. • To achieve minimum breakdown and to keep
the plant in good working condition at the
lowest possible cost.
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MAINTENANCE ENGINEERING
i. To ensure the availability of the machines and
services in an optimum working condition. PRINCIPLE OF MAINTENANCE
ii. To keep the time schedule of delivery to the
customer or to section of further processing • It is followed in a system to guide the staff to
work efficiently to achieve the overall
iii. To meet the availability requirements for objectives of the maintenance system.
critical equipments. • The main area of work governed by these
iv. To keep the maintenance costs as low as principles are:
possible for non critical equipment. Production and maintenance objectives
v. To meet the quality requirements of the Establishment of work order and recording
product. system
Plant management in maintenance work
Information based decision making IMPORTANT FACTORS TO BE CONSIDERED
IN MAINTENANCE PLANNING
Planning of maintenance functions It includes the following
Job distribution
Adherence to planned maintenance strategy Programme
Manpower allocation
Manpower for maintenance Staffing
Planning technique
Workforce control Planning procedures
Estimation of maintenance work
Maintenance control.
Role of spare parts
Training the maintenance workforce
Combined preventive and emergency • Policies
maintenance planning Fault oriented maintenance polices are
evolved by the maintenance department .
• ORGANISATIONAL GOALS
• Maintenance planning must be in accordance
These policies should identify the level of
with that of the organization goals.
maintenance required for different assets in
• MAINTENANCE NEEDS ANALYSIS should be the organization
carried out to identify the role of piece of
equipment in achieving the desired objectives
of the organization. It also formulates the procedures of
conducting maintenance operations
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MAINTENANCE ENGINEERING
IMPORTANCE AND BENEFITS OF SOUND
• PROCEDURES
MAINTENANCE MANAGEMENT SYSTEM
The maintenance planning involves
determining the methods to carry out each of
The capital cost and operating costs are the
the maintenance functions .
major factors involved in any industrial
investment.
The procedures of the work must be well The life of equipment and maintenance
defined and standardized without any schedule information provided by
confusion to the workforce. manufactured may not realized in practice to
make the need for having a sound
management system
THE BENEFITS RELIABILITY
Minimization of downtime It is defined as the probability that a component/
Improvement in availability of system system.
Conditions: 1) Operating under the given condition and 2) will
Extended life of equipment perform its intended functions adequately for specified period
of time.
Safety and smooth operation of the process
Provide adequate back up supply IMPORTANCE
Minimization of normal expected wear and Sudden failure of any component make huge of
tear of the equipment production, accident and interruption in the
Increased reliability of the system service continuity.
Provide proper working environment TYPES:
1. Inherent reliabilty
Cost effective maintenance
2. Acheivable reliability
DETERMINATION OF RELIABILITY
4 important factors FAILURE PATTERN OF EQUIPMENT:
Reliability expressed as probability I Phase
Adequate performance requirement II Phase
Duration of adequate performance III Phase
Environmental or operating conditions
FAILURE PATTERN OF EQUIPMENT: Phase I
Phase II
Phase III
I Phase
II Phase
Failire rate,x
III Phase
Time, t
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MAINTENANCE ENGINEERING
FAILURE INTENSITY: Normal distribution
• Failure density during the first unit interval = f d1 = n1/N
• Failure density during the second unit interval = f d2 = n2/N
• Failure density during the ith unit interval = f d1 = ni/N
• Let 1 be the last interval after which there are no survivors. Then Y=
• f dl = nl /N Where is the average population and σ is the standard deviation of the
• Then population.
f d1 + f d2 + f d3 +……………+ f d1 = nl/N + n2 /N+ N + n3 / N + ……….+ n/N
Exponential probability Distribution
The equation for the exponential probability distribution is given by
• = N/N= 1
Y= e
Weibull Probability Distribution:
The equation for Weibull probability distribution is given by
PROBABILITY OF FAILURE
Ratio of number of units that failed at specified
Where n is the characteristic load factor,
period of time to the total population
is the curve shape parameter and Mean failure rate (h)
Mean Time To Failure (MTTF)
is the location parameter.
Mean Time Between Failures (MTBF)
Mean Time To Repair (MTTR)
Maintenance action rate
MAINTAINABILITY AVAILABILITY
It is defined as the probability that a unit or It is defined as the ratio of the time at which
system will be restored to specified working equipment is available for the designated
conditions with in a given period when operation / service to the total time of the
maintenance action is taken in accordance with operation and maintenance of equipment.
prescribed procedures and resources. 3 types of availability
The numerical value of maintainability lies in Inherent availability
between 0 & 1. Achieved availability
Operational availability
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MAINTENANCE ENGINEERING
INHERENT AVAILABILITY Maintenance organization:
Inherent availability= MTBF • To ensure that the maintenance functions
MTBF +MTTR
are carried out effectively to reduce the
Achieved availability= MTBM (Mean Time B/W Maintenance) production loss.
MTBM +M (Mean active maintenance)
Operational availability= MTBM 3 basic necessary components:
MTBM +MDT (Mean down time) Resources
Administration
Work planning and control system
Comples function = f(Rs , Ms, Se)
Relaiability , Maintainability and supply effectiveness
Tasks of Maintenance Organization: MAINTENANCE FUNCTION AND ACTIVITIES
Identifying areas for implementation of
Identification of organization rolls
preventive maintenance program
Determination of maintenance work load Making suitable arrangements for maintenance
Uniform distribution of total maintenance work facilities for carrying out the maintenance work
Identification and assignment of essential properly.
works to the various sections. Planning and scheduling the total maintenance
work.
Proper knowledge and proper training to the
staff about maintenance. Ensuring proper and timely supply of spare parts.
Standardization of maintenance work.
Designing the policies and procedures.
Training of maintenance personnel.
Implementation safety norms and procedures.
Ensuring safety of personnel and equipment LINE ORGANIZATION
Types of maintenance organization:
1. Decentralized General Foreman
2. Centralized
3. Partially centralized Foreman
There are basically two types of organization are
Foreman (Mech)
(Elec)
followed in most of the industries. They are
(i) Line organization and
(ii) Line staff organization Crew Members Crew Members
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MAINTENANCE ENGINEERING
LINE STAFF ORGANIZATION MAINTENANCE FUNCTIONAL
ORGANIZATION
General Maintenance
Foreman Engineer
Foreman Foreman
Storekeep Cheif
(Mech) (Elec) Clerk
er Foreman
Crew Crew
Foreman Foreman Foreman Foreman
Members Members Welding shop Hydraulic shop
Engine shop Electrical shop
Centrally controlled AREA MAINTENANCE
Maintenance Organization ORGANIZATION
Maintenance Area Cheif
Superintendent Engineer
Maintenance Administration Maintenance Production
Engineer Engineer Engineer Engineer
General General GeneralForema Foreman Mechanical Lubrication Instrumentation Document
Foreman Foreman Elec n Service Fabrication Engineer Engineer Engineer Engineer
(Mech)
Planning Workshop
supervisor Superintendent
MAINTENANCE ECONOMICS:
Organization Structure
Life style cost analysis
Estimation of economic life of equipment
Maintenance Production Maintenance cost
Fixed cost
Superintendent Engineer
Variable cost
Facilities
Foreman
Foreman
shopmaintenan
Foreman
planning &
Foreman
Engineering
MAINTENANCE BUDGET:
ce maintenance Appropriation Budget
Fixed Budget
Field Foreman Variable Budget
