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Introduction : Plant implies all physical means of production in a manufacturing

system. These can be machine tools , fixtures, land, building and other facilities.
These facilities are subject to deterioration due to their use and exposure to
environmental conditions. The process of deterioration if not checked or rectified or
reconditioned may make these facilities unserviceable after some time. This
checking and rectification is done through the process of maintenance. This means
that the facilities have to be maintained to the desired level of efficiency i:e to keep
assets in satisfactory condition or restore these to the condition. Maintenance
ensures conditions of the facilities such that it permits uninterrupted
implementation of plan requiring their use.

Maintenance management is concerned with planning and controlling routine

planned and preventive maintenance activities of an organization. Through
streamlining of maintenance activities is essential before an attempt is made to set
standards.

Objectives of plant maintenance

The management of maintenance activity has to concern itself with uninterrupted
production process at minimum cost and maximum reliability.
•To maximize the amount of time the assets will be available for use for the
purpose for which these were procured
•To preserve the value of the assets by reducing the rate at which they deteriorate.
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• To perform the activities of maintenance in the most economical manner.
• To plan and schedule maintenance work so as to anticipate and prevent
interruptions in operations.

Functions of maintenance management

• Inspection – Maintenance inspection involves periodic inspection of machines and
equipment to ensure safe and efficient operation making sure that the equipment
requiring work at specified periods receives proper attention. It implies detection
of faults before they develop into breakdown of the equipment. It is an expensive
strategy and has to be used selectively.
• Repair – When an item or its component breakdowns, then the process of
repairing the component or replacing the item or part of it by another item to
restore the item in working order is known as repair.
• Overhaul – This is another routine and regular maintenance function falling under
preventive maintenance. The frequency of overhauling is far less than inspection
and lubrication. Here the machine is stripped and the various parts are cleaned
and oiled and critical components replaced. (See video)
• Lubrication – Proper lubrication is the essence of any good maintenance system.
The cause of most of the breakdowns will be traced to failure of lubrication
converts solid friction into fluid friction, thereby reducing the gradual damage to
the moving parts considerably. It prolongs the life of the equipment. Proper
lubrication means the use of the right lubricant and to take care to prevent
contamination. Contaminated oil spoils the life of the equipment. See next slide
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 Rolling Mill Back Up Rolls Oi
l
Work Rolls

Barrel
Tank Under CRM with Filter Oil Tank in Oil Tank
Cellar
Ground Level
Cellar
Heat Exchanger
Vaccumatic Paper Bed
Filter
Magnetic
Filter

Tramp
Oil
Valve
Tank
Pump Filter Mesh
Dirty Tank Clean Tank Agitator 4
 Motor

Guide Rollers
Press
Floor Level

Control Back Up Roll

Panels Motor

Work Roll HR Coil

Cellar Area 5
• Salvage - Any item/equipment is classified as salvage when it cannot be required
or cannot be brought to the desired level of performance. In that case the item is to
be replaced by a new one to bring back the system into operation.

Types off plant maintenance

Breakdown maintenance – This is also known as corrective maintenance. For non
critical equipment it is usually the policy to allow it to run without much routine
attention. The breakdown of any equipment is a random phenomenon, however the
consequences of severe breakdowns can be forestalled considerably by repairing
the equipment as expeditiously as possible by planned maintenance and provision
of spares and maintenance of man hours. Breakdown maintenance practice is
economical for those equipment whose downtime and repair costs are less. It is
administratively easier and needs smaller staff. The breakdown maintenance
strategy can be formulated by analyzing the causes of breakdown.
• Failure to identify and replace worn-out parts.
• Lack of lubrication.
• Inefficient or neglected cooling system.
• Too low or too high voltage.
• Use of substandard or wrong fuel.
• Indifference towards vibrations/sound in the system.
Disadvantage of Breakdown maintenance.
• It results in dislocating the production process or causes excessive delays or
reduction in output.
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• Wages are to be paid for idle time resulting in loss of profit.
• Failure of machines can cause accidents leading to loss of life.
• There may be more material wastage.

Preventive maintenance
All machines deteriorate with use and exposure. Deterioration of machine implies
change in dimensions of its various components and weakening of its members
due to fatigue, impact and corrosion. Such deterioration is indicated by-
• Inability of the machine to take specified load.
• Reduction in speed of the machine.
• Deterioration in quality of the output by the machine.
• Reduction of operational life of the machine.
This process of deterioration if not checked will increase the cost of production but
will also result in the stoppage of the machine due to breakdown of its parts.
Preventive maintenance involves periodic cleaning, servicing, inspection and
replacement of worn out parts.
Advantages of preventive maintenance
• Less production downtime because of fewer breakdowns.
• Lesser overtime payments for maintenance worker and repairs than for breakdown
repairs.
• Fewer large scale repairs and fewer repetitive repairs.
• Fewer product rejects, less spoilage, better quality control.
• Lesser standby equipment requirements thus reducing capital investment.
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• Better spare parts control leading to minimum inventory level.
• Ensures greater safety to workers.
• Reduction in maintenance cost.
• Lower unit cost of manufacture.

Total productive maintenance

Total productive maintenance (TPM) philosophically represents Total Quality
Management (TQM) in several aspects such as
• Total commitment to the program by upper level management is required.
• Employees must be empowered to take corrective action.
• A long range outlook must be accepted as TPM may take a year or more to
implement and is an ongoing process.
Change in employee mindset towards their job responsibilities must take place
as well. TPM brings maintenance into focus as a necessary and vitally
important part of business. It is no longer regarded as a non profit activity.
The goal is to hold emergency and unscheduled maintenance to a
minimum. New technologies i:e new machines requires skills beyond the
competence of the maintenance operator. Each and every person has to be
involved from top management to shop floor workers.
The dual goal of TPM is zero breakdowns and zero defects. When breakdowns
and defects are eliminated, equipment operation rates improve, costs are
reduced, inventory can be minimized
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A complete definition of TPM includes the following five elements
•TPM aims to maximize equipment effectiveness.
•TPM establishes a through system of preventive maintenance or the
equipment's entire lifespan.
•TPM is implemented by various departments viz. engineering, operations,
maintenance.
•TPM involves every single employee from top management to workers on the
shop floor.
•TPM based on promotion of preventive maintenance through motivation,
autonomous small group activities.
In the US the maintenance department carries out the preventive maintenance
but in Japan the entire management and workers work towards TPM.

Daily equipment check up, lubricating, cleaning, inspection the deterioration can
be prevented and potential equipment failures averted. Daily maintenance is the
responsibility of the operator of the machine.

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