CHAPTER#17 ENGINEERING MAINTENANCE MANAGEMENT Lecture No. 16Course: Engineering Management MED DEPARTMENT, U.E.T TAXILA COURSE INSTRUCTOR : PROF. DR. SHAHAB KHUSHNOOD

What is the difference b/w MAINTENANCE & MAINTENANCE ENGINEERING ……….. ?

Maintenance “Maintenance” means to keep equipment in operational condition or repair it to its operational mode. Its main components are:  Preventive Maintenance  Corrective Maintenance Preventive Maintenance is the maintenance which is carried out to prevent/avoid the upcoming breakdowns. Corrective Maintenance is the maintenance which is carried out to avoid the reoccurrence of the same breakdown.

Maintenance Engineering Its main objective is to ascertain that the new products are designed for ease of performing maintenance and that the proper economic support subsystem is provided at the moment of need.

Maintenance Engineering Department Functions Maintenance of installed equipment and facilities. Installation of new equipment and facilities. Modification of already installed equipment and facilities. Inspection and lubrication of existing equipment. Management of inventory. Disposal of waste and salvage. Production of utilities. Administration. Supervision of manpower. Keeping records.

Maintenance Manual It contains:  Policies  Objectives  Procedures  Organization concerning execution of maintenance functions.

Why Maintenance Manual is Needed….?

Due to following reasons maintenance manual is important in an organization:  Unclear authority  Unclear responsibility  Execution bureaucracy  Incomplete procedures  Existence of duplicated effort and facilities

Objectives of Maintenance Engineering

An Approach For Upgrading Maintenance This approach is composed of following steps: 1.Determine the existing deficiencies. 2.Set goals for maintenance improvement 3.Establish priorities by taking into consideration the saving from each project under study. 4.Select indices to measure performance of each objective. 5.Establish plans for both short and long term. 6.Implement plan. 7.Report status on a semi-annual basis. 8.Review the plan at the end of each year.

Effective Maintenance Management The important components of managing maintenance function:  Maintenance Policy  Control of materials  Preventive maintenance  Work order  Job planning  Priority and backlog control  Data recording system  Performance measurement indices  Work measurement

Maintenance Policy Document which clearly describes the policies, objectives, authorities, responsibilities, maintenance performance measuring techniques.

Control of Materials  Material control is a important perspective for the efficiency of the maintenance organization.  The improper control of materials may be the cause for the delay in performing maintenance, false start, ineffective utilization of manpower.  One of the important problems of the material control is the inventory control.

Inventory Control Model Following symbols were used to develop equations for the model.

Example

Solution

Preventive Maintenance This is performed to keep equipment in satisfactory working condition by providing inspection and correction of early stage malfunctions. During preventive maintenance following factors must take under consideration.  Economics(maintenance cost is compared with downtime cost)  Standards compliance(government, insurance, professional, fire, safety standards)  Process Reliability(critically consideration of production schedule deadlines )

Preventive Maintenance Benefits  Reduction in catastrophic failures  Reduction in maintenance costs.  Reduction in production downtime  Reduction in overtime payment for the maintenance workers  Reduction in the requirement of the backup equipment  Reduction in the manufacturing unit cost.  Improvement in safety for workers

Work Order The purpose of work order is to authorize and direct an individual or a group to carry out a specified task. Work order should include following information: The requested and planned completion dates. The planned start date Work description and its reasons. Cost of materials. Cost of labor. Approval signatures. Work category(i.e: repair, installation) Affected items. Job planning

Job Planning For effective maintenance management following items have to be planned:  Procurement of tools, materials, components.  Security safety permit.  Delivery of tools.  Methods and sequencing  Development of designs.

Data Recording System The data recording system is used to keep various types of equipment or property records. These records are classified into four catagories: 1.Maintenance costs records 2.Work performed records 3.Inventory records 4.Files records (warranties, drawings etc)

Performance Measurement Indices Index I This index is known as the broad indicator and is defined as: I 1 =C tmc /P o Where I 1 is the index parameter. C tmc is the total sum of maintenance costs P o is the total output