Introduction to Maintenance
Prof. Dr. Mohammad Younas
ChE 401 Plant Safety & Maintenance Engrg.
Semester 6
Sparing 2019 1
Imagine
Spillage, ignition in Oil and gas industry
Moving parts in cement industry
Flame temperature in rotary kiln
Exhaust of chemicals in a chemical industry
…………………………….
In spite of maintenance work, accident still
occurs
Imagine having no maintenance system
2
Maintenance and reliability is important
Maintenance and product quality
Maintenance and productivity
Maintenance and safety
Maintenance and supply chain, JIT
Failure cause disruption, waste,
accident, inconvenience and expensive
3
Operators less able to do repairs
themselves
Machine and product failure can have
effect on company’s operation and
profitability
Idle workers, facility
Losses due to breakdown
4
Failure
Failure – inability to produce work in
appropriate manner
Equipment / machine failure on production
floor – worn out bearing, pump, pressure
leaks, broken shaft, overheated machine etc.
Equipment failure in office – failure of power
supply, air-conditioned system, computer
network, photocopy machine
Vehicle failure – brake, transmission, engine,
cooling system
5
Maintenance in Service
Industry
Hospital
Restaurants
Transport companies
Banks
Hotels and resorts
Shopping malls / retail
Gas station
6
Maintenance in Manufacturing
Companies
Electronic
Automotive
Petrochemicals
Refinery
Furniture
Ceramics
Food and beverages
7
Maintenance
All actions necessary for retaining an
item, or restoring to it, a serviceable
condition, include servicing, repair,
modification, overhaul, inspection and
condition verification
Increase availability of a system
Keep system’s equipment in working
order
8
Question?
Why do we need maintenance?
What are the costs of doing
maintenance?
What are the costs of not doing
maintenance?
What are the benefits of maintenance?
How can maintenance increase
profitability of company?
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Purpose of
Maintenance(PBLR)
Attempt to maximize performance of
production equipment efficiently and
regularly
Prevent breakdown or failures
Minimize production loss from failures
Increase reliability of the operating
systems
10
Principle Objectives in
Maintenance(QUHIC)
To achieve product quality and customer
satisfaction through adjusted and serviced
equipment
Maximize useful life of equipment
Keep equipment safe and prevent safety
hazards
Minimize frequency and severity of
interruptions
Maximize production capacity – through high
utilization of facility
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Problems in
Maintenance(ACQTP)
Lack of management attention to
maintenance
Little participation by accounting in analyzing
and reporting costs
Difficulties in applying quantitative analysis
Difficulties in obtaining time and cost
estimates for maintenance works
Difficulties in measuring performance
12
Problems Exist Due To:
Failure to develop written objectives and
policy
Inadequate budgetary control
Inadequate control procedures for work order,
service requests etc.
Infrequent use of standards
To control maintenance work
Absence of cost reports to aid maintenance
planning and control system
13
Maintenance Objectives
Must be consistent with the goals of
production (cost, quality, delivery,
safety)
Must be comprehensive and include
specific responsibilities
14
Maintenance Costs
Cost to replace or repair
Losses of output
Delayed shipment
Scrap and rework
15
Types of Maintenance
Maintenance may be classified into four categories:
(some authors prefer three categories- scheduled
and preventive maintenances are merged)
Corrective or Breakdown maintenance
Scheduled maintenance
Preventive maintenance
Predictive (Condition-based) maintenance
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Corrective or Breakdown
Maintenance
Corrective or Breakdown maintenance
implies that repairs are made after the
equipment is failed and can not perform its
normal function anymore
Quite justified in small factories where:
– Down times are non-critical and repair costs are
less than other type of maintenance
– Financial justification for scheduling are not felt
17
Disadvantages of Corrective
Maintenance
Breakdown generally occurs inappropriate times
leading to poor and hurried maintenance
Excessive delay in production & reduces output
Faster plant deterioration
Increases chances of accidents and less safety for
both workers and machines
More spoilt materials
Direct loss of profit
Can not be employed for equipments regulated by
statutory provisions e.g. cranes, lift and hoists etc
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Scheduled Maintenance
Scheduled maintenance is a stitch-in-time
procedure and incorporates
– inspection
– lubrication
– repair and overhaul of equipments
If neglected can result in breakdown
Generally followed for:
– overhauling of machines
– changing of heavy equipment oils
– cleaning of water and other tanks etc.
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Preventive Maintenance (PM)
– “Prevention is better than cure”
Principle
Procedure - Stitch-in-time
It
– locates weak spots of machinery and equipments
– provides them periodic/scheduled inspections and
minor repairs to reduce the danger of unanticipated
breakdowns
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Candidates for Preventive
Maintenance
Frequency of Failure
Good candidates
have more normal
distribution with
low variability
Mean Time Between Failure (MTBF) 21
Advantages of PM
Advantages:
–Reduces break down and thereby down time
–Lass odd-time repair and reduces over time of
crews
–Greater safety of workers
–Lower maintenance and repair costs
–Less stand-by equipments and spare parts
–Better product quality and fewer reworks and
scraps
–Increases plant life
–Increases chances to get production incentive
bonus
22
Predictive (Condition-based)
Maintenance
Inpredictive maintenance, machinery
conditions are periodically monitored and this
enables the maintenance crews to take timely
actions, such as machine adjustment,
repair or overhaul
Itmakes use of human sense and other
sensitive instruments, such as
–audio gauge, vibration analyzer, amplitude meter,
pressure, temperature and resistance strain
gauges etc.
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Predictive Maintenance (Contd.)
Unusual sounds coming out of a rotating
equipment predicts a trouble
An excessively hot electric cable
predicts a trouble
Simple hand touch can point out many
unusual equipment conditions and thus
predicts a trouble
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Maintenance Costs
Cost
Breakdown Cost
Maintenance
Commitment 25
Maintenance Costs
Cost
PM Cost
Breakdown Cost
Maintenance
Commitment 26
Maintenance Costs
Cost
Total Maintenance Cost
PM Cost
Breakdown Cost
Maintenance
Commitment 27
Maintenance Costs
Cost
Total Maintenance Cost
PM Cost
Breakdown Cost
Optimal Maintenance
Commitment 28
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Determining the Size of Repair Crews
Problem:
A factory has 200 machines and the maintenance
engineer supervises the repair crews who repair
malfunctioning machines. The maintenance policy is
to repair the broken down machine and bring back in
production within 2 hours on the average. If average
breakdown rate is 3.5 machines/hour and each repair
crew can repair 0.25 machine per hour on the
average. How many repair crews are required ?
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Solution
The formula for average repair rate () is
1
ts = ---------- or = + 1/ ts
-
Where = repair rate
= arrival rate of malfunctioning machines
ts = average time arrivals in the system
Required average repair rate
= 3.5 + 1 / 2 = 4 machines / hour
No. of Crews = machines/hour a crew can repair
= 4 0.25 = 16 repair crews required
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