NEED FOR MAINTENANCE

MAINTENANCE

• Maintenance is an important factor in quality assurance, which

is another basis for the successful competitive edge.
Inconsistencies in equipments lead to variability in product
characteristics and result in defective parts that fail to meet
the established specifications. Beyond just preventing break
downs, it is necessary to keep equipments operating within
specifications (i.e. process capability) that will produce high
level of quality.
MAINTENANCE OPERATIONS MANAGEMENT SUPPORTS FOUR
MAIN CATEGORIES OF MAINTENANCE:

• Providing maintenance responses to equipment problems

• Scheduling and performing maintenance on a periodic cycle based
on time or cycles
• Providing condition-based maintenance derived from information
obtained from the equipment or inferred about the equipment
• Optimizing resource operating performance and efficiencies
 OBJECTIVES OF MAINTENANCE
 Minimizing the loss of productive time because of equipment
failure (i.e. minimizing idle time of equipment due to break
down).
minimizing the repair time and repair cost.
 Minimizing the loss due to production stoppages.
 Efficient use of maintenance personnel and equipments.
 Prolonging the life of capital assets by minimizing the rate of
wear and tear.
To maximize efficiency and economy in production through
optimum use of facilities.
 To minimize accidents through regular inspection and repair of
safety devices.
To minimize the total maintenance cost which includes the cost of
repair, cost of preventive maintenance and inventory carrying costs,
due to spare parts inventory.
 To improve the quality of products and to improve productivity.
 To keep all productive assets in good working conditions.
 FUNCTIONS OF MAINTENANCE
INSPECTION:

Periodic checking of machines

Giving proper attention to those equipments required work in intervals
Determination of repair feasibility
Control of quality work
Detection of faults before breakdown of equipment.
 REPAIR:

Process of repairing the component or replacing the item or part by

another item to restore failed or broken down item in working order.

OVERHAUL:

Falls under preventive maintenance.

Frequency of overhauling is less than lubrication and inspection.
Here the machine is stripped and the various parts are cleaned and oiled
and components are replaced.
LUBRICATION:
Helps in maintaining the machine accuracy and increase life of
machine
It is done by the operator himself.
Lubrication can be daily, weekly, fortnightly, monthly.

SALVAGE:
• Transport or insurance to save goods from being damaged or destroyed ,
especially from a ship .
 TYPES OF MAINTENANCE
BREAKDOWN (REACTIVE) MAINTENANCE:
 Breakdown maintenance is basically the ‘run it till it breaks’ maintenance
mode. no actions or efforts are taken to maintain the equipment as the
designer originally intended to ensure design life is reached. Studies as
recent indicate that, this is still the predominant mode of maintenance.
 Advantages to breakdown maintenance can be viewed as a double-
edged sword. If we are dealing with new equipment, we can expect
minimal incidents of failure. If our maintenance program is purely
reactive, we will not expend manpower or incur capital cost until
something breaks. Since we do not see any associated maintenance cost,
we could view this period as saving money.
PREVENTIVE MAINTENANCE:

 Preventive maintenance can be defined as, “actions performed on a time

or machine-run-based schedule that detect, preclude, or mitigate
degradation of a component or system with the aim of sustaining or
extending its useful life through controlling degradation to an acceptable
level.” Preventive maintenance is a means to increase the reliability of
their equipment.
 By simply expending the necessary resources to conduct maintenance
activities intended by the equipment designer, equipment life is extended
and its reliability is increased.
PREDICTIVE MAINTENANCE:

 Predictive maintenance can be defined as “measurements that detect

the onset of a degradation mechanism, thereby allowing causal stressors
to be eliminated or controlled prior to any significant deterioration in the
component physical state. Results indicate current and future functional
capability”.
 Basically, predictive maintenance differs from preventive maintenance by
basing maintenance need on the actual condition of the machine rather
than on some preset schedule. Preventive maintenance is time-based.
 ADVANTAGES OF GOOD MAINTENANCE
• Life of machinery and equipments are increased.
• Production takes place as per the schedule.
• Products are delivered to customers in time and hence high level of customer
satisfaction can be expected.
• Machines are in good condition. Hence quality of the products will be good.
• No production loss.
• Machinery is not damaged.
• No idle time of men and machines . Hence their utility increases.
 DISADVANTAGES OF POOR MAINTENANCE
• Machinery may be damaged .this is a loss.
• Poorly maintained machines will produce poor quality products.
• More wastage of materials.
• Break down of machines makes both men and machine in idle position .
So production time is wasted . This will increase cost of production.
• Poor maintenance cause accidents.
• Due to poor maintenance life of machine is reduced.
THANK YOU