1. Modern Maintenance. Management
By Jayprakash Komiya
Manager (Mech)

2. What is Maintenance It represent a set of measures and action that ensures an equipments prevention, preservation or restoring in an anticipated state or capable to guarantee a certain services altogether with the minimizing of the maintenance cost. Modern maintenance Modern maintenance management is not to repair broken equipment rapidly. Modern maintenance management is to keep the equipment running at high capacity and produce quality products at lowest cost possible.

3. Until the 60’s activity of maintenance was synonyms with repairing Why to consider change in maintenance strategies: . Increasing demand of production. . Production plan changed from 16 hours production to 24 hour production . . High downtime cost of plant and equipment . To maintain/improve the quality of products

4. Basic cycle of maintenance
Work Identification
Work Planning
Work Scheduling
Work Execution
Analysis
History Recording

5. The basic function of a maintenance management system can be :
Preventive maintenance
Plant and unit record(Equipment)
Inventory and spare parts control system
Document record
Planning system for maintenance and work order routines
Technical/economic analysis of plant history, maintenance and machine availability

6. Types of Maintenance Corrective or Break Down Maintenance
Planned or Preventive Maintenance
Predictive or Condition Based Maintenance
Total Productive Maintenance
Reliability Centered Maintenance

7. Types of Maintenance Corrective Maintenance Repair it when it fails
Break-down
Time
Cost
Corrective
Maintenance
Repair it when it fails
Preventive
Maintenance
Maintenance at regular intervals
Time
Cost
Time
Cost
Predictive
Maintenance
Problem detected before predicted failure.
Maintenance planned ahead

8. Corrective Maintenance - Break-down Maintenance -
Not
recommended
for critical
machines
Corrective Maintenance leads to:
Secondary damage
Safety risk
Unplanned downtime
Unplanned maintenance
Product waste
Spares inventory
Time
Cost

9. Preventive Maintenance - Time-based Maintenance -
Not
recommended
for critical
machines
Time
Cost
Time-based Preventive Maintenance involves:
More frequent overhauls
Risk of early failures
Tampering with good machines
Time consuming overhauls
Experts needed for each overhaul

10. Predictive Maintenance
Recommended
for critical
machines
Break-down
Time
Cost
Monitor the condition of the machine and predict when it would fail
Plan maintenance ahead of time and save money
Repair the machines only when they need to
Focus overhauls only on faulty parts
Higher plant availability, performance and reliability
Greater safety
Better product quality
Attention to environment
Longer equipment life
Greater cost effectiveness

11. Condition Monitoring Techniques
Visual Monitoring
Thermography
Vibration Monitoring
Shock pulse Monitoring
Temperature Monitoring
Wear Debris Analysis
Motor Current Monitoring
Noise monitoring and analysis

12. Predictive Maintenance (PdM) and
Condition Monitoring

13. Machinery Health Management
Diagnosing a machine is just like a person:
Vibration:
The ‘pulse’ of the machine
Oil:
The ‘life blood’ of the machine
Motor Current:
The ‘brain waves’ of the machine
Thermography:
‘Taking its temperature’
Total
Picture

14. Vibration Analysis Mechanical faults generate vibration
Apply pattern recognition and exception analysis
Use expert system to screen data
Fault Types
Misalignment
Imbalance
Bearing Defects
Gear Defects
Looseness
Belt Drive Problems
Electrical Problems
Cavitation

15. Trending Overall Vibration
Vibration severity
+ 4 steps
+ 3 steps
+ 2 steps
+ 1 step
Normal
Inspection,
minor repairs
Plan major
overhaul
(Shutdown)
Effect repairs
Routine
maintenance
(lubrication, etc.)
Vibration
measurement
Maintenance
activities
Breakdown

16. Shock Pulses from Bearings

17. Bearing & Lubrication Condition
Good Bearing, Sufficient Lubrication
Good Bearing, Insufficient Lubrication
Damaged Bearing

18. Infrared Thermography-Applications
Mechanical inspections
Bearings
Gears
Belts
Couplings
Motor insulation breakdown
Electrical equipment
Bad connections, breakers, fuses
Overloaded conditions
Motor Control Center components
Distribution lines
Cable trays/conduits

19. Thermograph of Electrical Panel
Eye - view
Thermal Image

20. Oil Analysis Examination of lubricants provides information about:
Chemical properties
Ability to lubricate machine and prevent adhesion wear
Contamination
Presence of foreign particles that might induce wear
Wear particles
Evidence of wear that has already occurred

21. Fundamental Concept
Four criteria are considered to evaluate condition:
SIZE : Severity of wear
SHAPE : Wear mechanism / Cause of wear
COMPOSITION : Wearing component
CONCENTRATION : Severity of wear

22. Predictive Maintenance (PdM) and
Condition Monitoring

23. Total Productive Maintenance
Total – Involves all functions and people at all levels Productive – Efficient and effective utilization of all the resources Maintenance – Keeping man-machine-material system in optimal condition. TPM can be defined as a structured equipment-centric continuous improvement process that strives to optimize production effectiveness by identifying and eliminating equipment and production efficiency losses throughout the production system life cycle through active team based participation of employees across all levels of the operational hierarchy.
TPM aims at achieving Zero breakdown, Zero defect, Zero accident, and Zero pollution.

24. The Pillars of TPM

25. Reliability Centered Maintenance(RCM)
Objective
Maintenance strategy optimization
Extension of equipment life span
Elimination of chronic machine problem
Root cause analysis
No preventive maintenance tasks to be performed- unless it can be justified
Definition
a process used to determine the maintenance requirement of any physical asset in its operating context.

26. Reliability-Centered Maintenance (RCM)

27. Evaluating Consequences with an RCM Decision Diagram

28. Maintenance ………..Assisting tools
Quality circles
Suggestion schemes
Continual improvement
Standardizing Management Systems
ISO 9001:2000 Quality Management System
ISO Environmental Management System
OHSAS Occupational Health and Safety

29. Objectives of Maintenance
During the years the maintenance function has not been seen as a condition for production output. The previous approach has been that maintenance is the necessary evil, one among the cost generators in the organization. Very often the maintenance strategy in plants has been to reduce the maintenance cost as much as possible without thinking of the consequences.
Objective of the maintenance is , as priority one , to create an availability performance which is suitable for production demands in the organization. No mechanized/atomized company has yet succeeded to produce with stopped equipment. Production buy availability performance from maintenance.

30. Changing approach of industries towards maintenance
PRODUCTION RESPONSIBILITIES Basic to the philosophy of planned maintenance is the concept that production is an equal partner with maintenance in the achievement of established goals. Production has certain obligations to maintenance: 1.  Production must accept maintenance as an equal partner. 2.  Production must continually attempt to optimize production. 3. Production equipment must not be abused. Higher than designed output is not  necessarily abuse. 4.  Lines of communication between production and maintenance must remain open.

31. Need of Motivation for Maintenance Staff -Maintenance is a thankless job”, this is repeated by us every time and also sometimes, How to Motivate the Maintenance personnel 1. Job Satisfaction 2. Recognition 3. Job rotation/enrichment 4. Reduced stress at work

32. CASE STUDY: SCREENING PLANT BD PATTERN

33. SCREENING PLANT AVAILABILITY & BREAKDOWN

34. THANK YOU