CHAPTER ONE

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 Imagine
 MAS flight Boeing 737 left KLIA at 2:00 pm
 All two engines, hydraulic systems working
 2:22 pm explosion shook plane
 Number 2 engine torn apart, 2 separate
hydraulic lines ceased to work
 In spite of maintenance work, engine still
failed
 Imagine having no maintenance system

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 You are not the only one if you experience:

 Equipment suffers unexplained shutdown and failures

or needs constant repair.

 Equipment operates at a slower speed than designed.

 Decreased productivity from machine-related problems.

 Does your equipment have excess capacity that could

be easily and inexpensively tapped?
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An older concept of Maintenance was
Maintenance is about preserving physical assets.

A newer concept is
Maintenance is all about:
preserving and caring for assets,
preserving the functions of assets,
preserving the inherent reliability of an asset,
preserving built-in capability of any asset,
satisfying customer requirements.

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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
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Maintenance in Service Industry
Hospital
Restaurants
Transport companies
Banks
Hotels and resorts
Shopping malls / retail
Gas station

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Maintenance in Manufacturing Companies
Electronic
Automotive
Petrochemicals
Refinery
Furniture
Ceramics
Food and beverages

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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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Wear and tear of means of production

- Tools or dies wear out by friction with the work

piece
- Machines parts wear out by friction with one
another
- Atmospheric conditions destroy the machine
points and materials.
- Aging also affects materials
- Improper handling of materials affects
equipment and material
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Product failure rate
 The Bath Tub Model – Three stages of new parts
1. Infant morality stage
2. A fairly long run stage
3. Wear out stage

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Any means of production must be
- used
- checked
- serviced
- tended
to give the full function which they are designed for.

The last three necessities constitute what is called

maintenance, whereas the former is operational.

From the engineering viewpoint, the management

of the means of production has two elements to it.
First, it must be maintained, and second, from
time to time it may also need to be modified
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Definition:
maintain is defined as
- cause to continue (Oxford Dictionary), or
- keep in an existing state (Webster Dictionary).
Maintenance can be considered as a combination of
actions carried out in order to replace, repair,
service, modify the components, or some
identifiable group of components, of a
manufacturing plant so that it will continue to
operate to a specified availability or a specified time.
Maintenance is the totality of all measures directed
towards control (preservation and restoration) of the
performance of a plant.
Maintenance is an auxiliary process in a production
process directed towards a high effectiveness of the
main process.

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Maintenance activity is the systematic and scientific
upkeep of equipment for:
- prolonging life of the equipment,
- assuring instant operational readiness,
- optimal availability for production at all times, and
- making sure that safety of man and machine is
at no time jeopardized

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Maintenance is performed to:
- eliminate system failures and hazards
- in order to ensure that equipment continues to
work within design tolerances and
specifications.

This ensures that the defined functions and standards

of operations of the plant and equipment are
capable of being performed for the required period.

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Maintenance systems are dynamic because they are
influenced by other factors within the system.
For example, intuition, judgment and budget.

The interaction of the plant, equipment and inherent

characteristics of materials used in production and
maintenance have a direct impact on the behavior of
the maintenance system over time and on its
underlying structure, strategies, processes and
decision rules.

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 How Maintenance is Performed

Maintenance Manufacturer’ Depot service

Operator department s field service (return equipment)

Competence is higher as we
move to the right
Preventive
maintenance costs less and
is faster the more we move to
the left
Trends in the Evolution of Maintenance

According to John Moubray (Reliability-Centered

Maintenance), the evolution of maintenance since
the 1930's can be traced through three
generations based on three technical factors:

a) growing expectations of maintenance,

b) changing views on equipment failures, and
c) changing maintenance techniques.

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First Generation: This covers the period up to the
World War II.
During this period:
‑ industry was not highly mechanized,
‑ equipment was simple and over designed,
‑ downtime did not matter much,
‑ prevention of equipment failure did not have
high priority,
‑ failures were corrected as they occur.
As a result, there was no need for systematic maintenance
beyond cleaning, servicing and lubrication.
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Second Generation: During the war, demand for
good increased and supply of industrial outputs was
low. This led to increase in mechanization. During
this period:
‑ machines became numerous and more
complex,
‑ industry started to depend heavily on these
machines,
‑ downtime started to matter,
‑ the idea that equipment failures could and
should be maintained came up.

As a result, the concept of preventive maintenance and

maintenance planning and control systems grew up.
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Third Generation: Since the mid-seventies, new
expectations, new research and new techniques have
revolutionized maintenance. During this period:
‑ maximizing life of equipment has become
important,
‑ higher plant availability and reliability have
become very important,
‑ greater automation has been effected,
‑ quality standards, safety and environmental
consequences matter quite a lot,
‑ cost of maintenance is becoming central,

As a result: greater expectations and leading to new

research which in turn lead to new techniques. 22
GROWING EXPECTATIONS OF MAINTENANCE

Third
Third Generation:
Generation:
 Higher
Higher plant
plant availability
availability
 Greater
Greater safety
safety
 Better
Better product
product quality
quality
 No
No damage
damage to
to the
the
environment
environment
Second
Second Generation:
Generation:  Longer
Longer equipment
equipment life
life
First
First Generation:
Generation:  Higher
Higher plant
plant availability
availability  Greater
Greater cost
cost effectiveness
effectiveness
 Fix
Fix itit when
when itit  Longer
Longer equipment
equipment life
life
broke
broke  Lower
Lower costs
costs

1940 1950 1960 1970 1980 1990 2000

CHANGING MAINTENANCE TECHNIQUES

Third
Third Generation:
Generation:
 Condition
Condition monitoring
monitoring
 Design
Design for
for reliability
reliability and
and
maintainability
maintainability
 Hazard
Hazard studies
studies
 Small,
Small, fast
fast computers
computers
Second
Second Generation:
Generation:  Failure
Failure modes
modes and
and effects
effects
 Scheduled
Scheduled overhauls
overhauls analyses
analyses
First
First Generation:
Generation:  Systems
Systems for
for planning
planning and
and  Expert
Expert systems
systems
 Fix
Fix itit when
when itit controlling
controlling work
work  Multiskilling
Multiskilling and
and teamwork
teamwork
broke
broke  Big,
Big, slow
slow computers
computers

1940 1950 1960 1970 1980 1990 2000

 The new developments include:
• Decision support tools, such as hazard studies,
failure modes and effects analysis and expert
systems.
• New maintenance techniques such as condition
monitoring.
• Designing equipment with much greater
emphasis on reliability and maintainability.
• Major shift in organizational thinking towards
participation, team working and flexibility – shift
towards Total Productive Maintenance (TPM)
 1950 1960 1970 1980 1990

Breakdown Maintenance
1951 Evolution of Maintenance
Preventive Maintenance
1957
Corrective Maintenance
1960
Productive Maintenance
1971 TPM
Total Productive Maintenance

Time-based era Condition-based era

QC ZERO
A C
C C A
I C M
R I P
D A
C E I
L N G
E T N
(1971) 7
Types of Maintenance
MAINTENANCE

PLANNED UNPLANNED
MAINTENANCE MAINTENANCE
(PROACTIVE) (REACTIVE)

EMERGENCY BREAKDOWN

PREDECTIVE PREVENTIVE IMPROVEMENT CORRECTIVE

MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE

STATISTICAL CONDITION - DEFERRED REMEDIAL

ENGINEERING DESIGN -
- BASED BASED
SERVICES OUT

Shutdown Maintenance

WINDOW RUNNIN ROUTINE OPPORTU SHUTDOWN SHUTDOWN SHUTDOWN

G -NITY PREVENTIVE IMPROVEMENT CORRECTIVE
The Challenges of Maintenance
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

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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

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Involvement of Maintenance activities
Maintenance is related to profitability through:
- equipment output and equipment running cost.
- time taken for maintenance purposes.

The importance of maintenance increases with

industrialization.

The level of maintenance required at the equipment

operation stage is affected by factors at other stages
through which the equipment passes.
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- Design stage:
Reliability and maintainability are the important
factors which should be considered properly in
relation to performance of equipment, capital
and running costs.
- Installation stage:
Maintainability is an important factor to be
considered during the installation, for it is here that
maintenance problems become clear.
- Commissioning stage:
This is a stage of technical performance testing
and also a stage of where primary design faults are
located and designed out.
- Operational stage:
The operational stage is a stage of learning where
maintenance plays an important role.
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 OPERATIONAL INVOLVEMENT

MANUFACTURE COMMISSIONING OPERATION

SPECIFICATION DESIGN REPLACEMENT
INSTALLATION
- Conceptualization - Performance - Primary design - Design fault - Wear-out
- Reliabilty - Quality control fault control detection - Obsolescence
- Maintainability - Design fault - Technical - Maintenance
- Support system detection performance test optimization
- Maintainability - Maloperation
avoidance

LEARNING PERIOD

CONTINUAL FEEDBACK

Fig. 1.2 Equipment life-cycle

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Maintenance management
is the direction and organization of resources in
order to control the availability and performance of
an industrial plant to a specified level.

In maintenance management the problem is two-

dimensional:
i) Determination of size and nature of the

maintenance work load,

ii) Organization and control of labour, spares and

equipment to meet the workload.

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Function of maintenance work
Earlier the objective of maintenance function was
considered to optimize plant availability at minimum
cost.
Today it is being considered as "Maintenance affects all
aspects of business effectiveness and risk-safety,
environmental integrity, energy efficiency, product
quality and customer service, not just plant availability
and cost."

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 Maintenance Objectives, Planning and Control
Maintenance objectives, planning and control are
inter-related
Over lapping to some extent
Economic factor has to be kept in mind by all the
contributing departments of an organization
it cannot sustain for long without earning profit.
 Since the ultimate objective is profit, the
production infrastructure and facilities have to be
maintained at as minimum a cost as possible with
maximum efficiency and operational availability.

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 OBJECTIVES OF MAINTENANCE
Prevent
Prevent breakdown
breakdown
Elimination
Elimination of
of during
during operation
operation
future
future defects
defects
Forestall
Forestall rapid
rapid
wear
wear ofof Ensure
Ensure safety
safety
components
components during
during operation
operation

Productivity Improvement
through maximum
availability at
optimum cost
Enhance
Enhance
performance
performance
level
level Maximize
Maximize
operational
operational
efficiency
efficiency
Reduce
Reduce maintenance
maintenance Reduce
Reduce idle
idle hours
hours due
due to
to
cost
cost component
component
malfunctioning
malfunctioning
Unavailability cost = loss of in-service material,
production loss while in repair or, undergoing
preventive Maintenance.

Resource cost = corrective maintenance labour,

preventive maintenance labour,
maintenance equipment costs, and
spares usage and holding costs.

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Maintenance Control
An established maintenance organization and plan needs
to set-up a control system to ensure that the plan and
organization are continually updated. This control
system performs three main inter-related functions:
- Work control:
is a function of the maintenance organization and
its object is to match men, spares and equipment
to the maintenance workload. This function
includes
- location of plant failure,
- determination of the necessary corrective
action,
- the setting of priorities,
- co-ordination and control of resources.
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- Plant condition control:
is needed to achieve optimum plant
performance in the long term. Its function is
to:
- identify the most important problems,
- diagnose causes,
- prescribe solutions.
In doing this the alternative actions are:
- modification of preventive maintenance
policy,
- equipment re-design (in the early equip.
life, especially),
- changes in production policy. 39
- Maintenance cost control: Its functions are:
- to identify high cost areas of plant,
- to monitor the trend of maintenance
effectiveness,
- to provide information for
maintenance decision making,
- to facilitate maintenance budgeting.

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How to determine the optimum age of
replacement?
Computerized Maintenance System

Data Files Output Reports

Equipment file
with parts list Inventory and
purchasing reports

Maintenance Equipment
and work order parts list
schedule

Equipment
Repair history reports
history file

Data entry
Cost analysis
– Work requests (Actual vs. standard)
– Purchase
Inventory of requests
spare parts – Time reporting
– Contract work

Work orders
– Preventive
maintenance
Personnel – Scheduled
data with downtime
skills, wages,
etc. – Emergency
maintenance
A simplified Maintenance Model

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