Unit-1 ME-VIII SEM Maintenance Management

UNIT-1 (Introduction to Maintenance Management)

Introduction
LECTURE NO:-1
Introduction

Maintenance management is defined as the process of maintaining a company's assets

and resources while controlling time and costs, ensuring maximum efficiency of the
manufacturing process. Maintenance management has gone from a rather archaic,
tedious, handwritten process to a computerized maintenance management system
(CMMS) — a software that plans, tracks, measures and optimizes all forms of a
maintenance program in one central system.
Maintenance management isn't just a software system, however. It's a combination of
software, best practices and trained personnel all focused on the same goal.
Maintenance management programs are highly customizable and centered around the
type(s) of maintenance employed at a plant. Whether you're using a condition-based
maintenance program like predictive maintenance or a more time-based maintenance
program like preventive maintenance, it's important to focus your program on the type
of maintenance used and its role within your organization.
Why Maintenance Management Is Important
Maintenance management is vital in ensuring the long-term success of your
maintenance program by monitoring quality assurance, maintaining operational
efficiency and keeping assets in optimum running order. Properly maintained assets and
resources keep your production stable and greatly minimize the chances for unplanned
downtime. Unplanned downtime causes a snowball effect, leading to a spike in
unexpected costs associated with things like repairs (overtime labor, spare parts, etc.),
delayed shipments, lost revenue or complete breakdowns of machines.

The Objectives of Maintenance Management

All forms of maintenance management share the common objective of analysing
production and finding the best practices and processes within a specific field.
Analysing reports from a CMMS, for example, lets you control costs, schedule work
properly and efficiently, and ensure failures and breakdowns are kept to a minimum.
The main objectives of maintenance management include:
Cost control/budgeting:
Maintenance management tools provide managers with the information necessary to
properly allocate funds from the budget. Cost control is important because some costs
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Unit-1 ME-VIII SEM Maintenance Management

are a better use of the company's funds than others. For instance, a maintenance manager
might need to buy a replacement part for an asset. She might have to choose between a
cheaper part that's less durable and a more expensive, longer-lasting part.

Scheduling work/allocating resources:

Scheduling work and allocating the resources of time and labor so they're at their most
productive play a key role in efficiency. Maintenance management gives a manager
ultimate understanding of the overall process to help decide priority levels of various
activities. For example, if the maintenance manager needs to verify the timely delivery
of a product, she might be inclined to prioritize forklift maintenance to ensure the
product can be moved around the warehouse and onto the delivery truck without
interruption.

Compliance and regulations:

Maintenance management tools help organizations comply with regulations at the local,
state and federal levels. For instance, it may seem like the cheaper option to assign one
operator to a particular asset, even though the law states two employees should be
assigned for safety reasons.

Minimize downtime/loss:
A good maintenance management program helps mitigate the loss of productive time
due to failure by establishing a planned maintenance program. Fewer production
stoppages mean less lost revenue.
Extend asset life:
Organizations invest heavily in machinery. Maintenance management programs help
ensure equipment and infrastructure are always in good condition. Regular maintenance
extends the useful life of machinery, facilities and other components by minimizing
wear and tear.

Enhance equipment:
Spinning off the objective of extending the life of assets, maintenance management also
enhances existing equipment through modifications, extensions or new low-cost items.

Training:

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Unit-1 ME-VIII SEM Maintenance Management

Maintenance management programs should include training personnel in specific

maintenance skills; improving operational safety; advising on the acquisition,
installation and operation of machinery; and enhancing the quality of the finished

Uncover maintenance trends:

Looking into historical data helps managers get a clear picture of what exactly goes on
during day-to-day operations. CMMS software, for example, can uncover things like
why an asset seems to be consistently underperforming.

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Unit-1 ME-VIII SEM Maintenance Management

UNIT-1 (Introduction to Maintenance Management)

Functions of Maintenance
LECTURE NO:-2
Functions Of Maintenance

(1) To develop maintenance policies, procedures and standards for plant

maintenance systems.

(2) To schedule the maintenance work after due consultation with the
concerned production departments.

(3) To carry out repairs and rectify or overhaul planned

equipment/facilities for achieving the required level of availability and
optimum operational efficiency.

(4) To ensure scheduled inspection, lubrication oil checking, and

adjustment of plant machinery and equipment.

(5) To document and maintain record of each maintenance activity (i.e.,

repairs, replacement,modifications and lubrications etc.)
(6) To maintain and carry out repairs of building,utilities,material handling
equipment’s and other service facilities .
(7) To carry out and facilitate periodic inspections of equipment and
facilities to know their conditions related to their failure and stoppage of
production.

(8) To prepare inventory list of spare parts and materials required for
maintenance.

(9) To ensure cost effective maintenance.

(10) To forecast the maintenance expenditure and prepare a budget and to

ensure that maintenance expenditure is as per planned budget.
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Unit-1 ME-VIII SEM Maintenance Management

(11) To recruit and train personnel to prepare the maintenance workforce

for effective and efficient plant maintenance.

(12) To implement safety standards as required for the use of specific

equipment or certain categories of equipment such as boilers, overhead
cranes and chemical plants etc.

(13) To develop management information systems, to provide information

to top management regarding the maintenance activities.

(14) To monitor the equipment condition at regular intervals.

(15) To ensure proper inventory control of spare parts and other materials
required.

In terms of plants operations the functions of maintenance are:

(a) The plant must be available as and when required.

(b) The plant must not breakdown during actual operation state.

(c) The plant must operate in an efficient manner at required level of plant
operation.

(d) The down time must not interfere with production runs.

(e) The down time due to breakdown should be a minimum.

To accomplish these conditions there must be complete cooperation and

mutual understanding between maintenance and production departments.
There must be an effective maintenance policy for planning, controlling
and directing all maintenance activities.

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Unit-1 ME-VIII SEM Maintenance Management

The plant maintenance department must be well organized, adequately

staffed sufficiently experienced adequate in number to carry out corrective
and timely maintenance with the efforts in minimizing the breakdowns.

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Unit-1 ME-VIII SEM Maintenance Management

UNIT-1 (Introduction to Maintenance Management)

Organization and Administration of Maintenance System
LECTURE NO:-3
Introduction

Technological growth worldwide has brought out significant changes in equipment and
machineries.The new concept of complexity in design and manufacturing is possible by
the use of computers,Artificial intelligence,Knowledge based expert systems. These
phenomenal changes have necessitated The optimum utilisation of these sophisticated
equipments/Systems. to keep the system or equipment operational, the demand for
maintenance has also increased manyfold. with this in mind, development of
organisational setup for maintenance is of paramount importence. before setting up in
new maintenance organisation, it’s need, objectives, functions etic must be understood
clearly to make it a cost-effective proposition. now it is the concept of total production
maintenance is gaining momentum where workers are not divided such as maintenance
and production personnel and each of them is capable of undertaking any job. This adds
flexibility in the systems the normal conflict off production and maintenance personnel
Is avoided.

Objectives Of maintenance organisation

The importance of maintenance organisation grows with the increase size of the
industry. A small-scale industry may require a simple maintenance organisation
weather for men in charge, whereas, If the side of the industry increases the
complexities of the maintenance and therefore the maintenance operations, function and
organisation also grow in size. A highly trained a highly trained and component person
may be required to head the maintenance organisation or department.
The following points should be considered while setting up a maintenance organisation
1)The organisational goals Pertaining to the maintenance function must be identified
2)The maintenance workload should be determined before hand to achieve the desired
result
3)Total maintenance work should be properly and uniformly distributed among all
concern person to avoid conflict among the workers
4)The essential work should be a send clearly and definitely to various departments of
the maintenance organisation
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Unit-1 ME-VIII SEM Maintenance Management

5)Due consideration should be given two proper qualification of the workers while
assigning his particular job
6)The maintenance organisation should be Stafford with the best qualified and trained
people available
7)The policies and procedures should be clearly designed at an early stage to help
maintenance You To achieve the organisation goals

Organizational requirements

While setting up a new maintenance organisation The following parameters must be

kept in mind
Coordination
Success of an organisation depends on effective coordination and cooperation of the
people in the organisation for a prolific maintenance organisation it is essential to have
a clearly definite organisational chart indicating job description and unambiguous
definition of authority for each job
Maintenance engineer
The primary job of a maintenance engineer is to reduce the downtime of the equipment
or system under his supervision. therefore the maintenance engineer should be well
qualified, technically competent, knowledgeable end cost conscious in order to be a
effective and efficient leader of the maintenance group.
Attitude of personnel
The attitude of the working personnel in many instance is not always positive towards
accepting the modern facilities and techniques available for the maintenance function
under the existing conditions the maintenance personnel should be apprised Of the Liest
techniques availevel in the field of maintenance
Maintenance work control
The structure of the maintenance organisation should be such that there is always
sufficient manpower to survive the work. care should be taken to see that a balance is
always maintained between the supervisor and then number of workers to be supervised.
However there is no fixed rule to maintain the proper ratio of supervisor to workers.
Managerial functions
It is the duty of the supervisory staff to develop their subordinates to a required level of
proficiency. The working personnel should be properly motivated to attend high level
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Unit-1 ME-VIII SEM Maintenance Management

of the proficiency so that they can work freely, fearlessly to fulfil the organisational
objectives.
Capacity utilisation
The main function of the maintenance organisation should be to utilise the full potential
of its workers.During the selection of persons ,The value of each individual must be
assessed totally as it is seen that a person may be a very good engineer but a poor
manager however managerial qualities can be imparted with a proper training and
incentive and that's a good engineer can become a efficient manager as well.

Types of maintenance organisation

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Notes By: -Shekhar Kaushik (Assistant Professor-ME Department, MITRC)
Unit-1 ME-VIII SEM Maintenance Management

UNIT-1 (Introduction to Maintenance Management)

Maintenance Organization
LECTURE NO:-4
Organizational Problems
Maintenance organizations face various problems due to the nature of maintenance
work.to overcome these problems the maintenance organization with the cooperation
of the plant management and the production Department should try to fill up the
organization gaps arising out the following situations
a) The plant management must identify the objective of the maintenance organization
with the overall production strategy. sometimes the production Department does not
allow the maintenance personnel to take up the scheduled maintenance work as this
disturbs Their production target
b) The maintenance work is of valid nature’s the maintenance organization should
understand the difference between the routine and essential work so that the essential
work is carried out most of previously with the help of production Department
c)A clear distinction between field and shop work should be made so that the traditional
distinction between field and shop work should be made so that the traditional attitude
does not hamper the maintenance work. The Maintenance organization should try new
concepts for better work control procedures
as stated earlier, properly qualified and experienced person should only man the
maintenance organization. sometimes persons from other Department are also shifted
to the maintenance Department either on promotion or due to their unsuitability in their
respective departments which should be avoided as it may create serious problems in
the maintenance organization.

Types of Maintenance Organization

The maintenance organization can be of the following type

Decentralized
In large size plants located at different places the Inter unit communication is difficult.
in such cases the decentralized type of organization is the best. Which means that the
maintenance organization works under the direct control of a chief engineer in charge
of the production under this type of organization better coordination between the
production and the maintenance group is possible because of a common head of
organization Advantages of such type of organization are
1. Speedy decision due to better line and communication under single control

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Unit-1 ME-VIII SEM Maintenance Management

2. Maintenance and production people understand each others problem better

because of their common goals
3. Interchangeability of workforce even at manager level is also possible
4. Better training at the workers level can be arranged
5. Conflicts among workers are also reduced due to better coordination and
cooperation

Centralized
In small factory where communication between the Department is more, free
centralized type of maintenance organization is preferred. Which is placed under a chief
maintenance engineer or manager the total responsibility of the maintenance function
for the inter-factory lies with the chief maintenance engineer under this type of
organization the responsibilities and accountabilities of the work must be properly
specified for production as well As for maintenance personnel to successfully meet the
project goals.

Partial Decentralized
The partiality centralized organization which is the modified form of centralize type of
organization Is most suitable for projects that have units at far away locations . under
this type of maintenance organization the maintenance personnel attached to the
production unit carry out work at unit level for day to day maintenance however
important maintenance functions such as overhauling planned maintenance work
procurement of spare parts are kept under the charge of achieve maintenance engineer
at his central office all centralize work as well as maintenance planning and
documentation are done at the center maintenance workshop.

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Unit-1 ME-VIII SEM Maintenance Management

UNIT-1 (Introduction to Maintenance Management)

Failure Analysis
LECTURE NO:-5
Failure Mode and Effect Analysis
The Failure Modes and Effects Analysis (FMEA), also known as Failure Modes,
Effects, and Criticality Analysis (FMECA), is a systematic method by which
potential failures of a product or process design are identified, analysed and
documented. Once identified, the effects of these failures on performance and
safety are recognised, and appropriate actions are taken to eliminate or minimise
the effects of these failures. An FMEA is a crucial reliability tool that helps avoid
costs incurred from product failure and liability. Project activities in which the
FMEA is useful:
☛ Throughout the entire design process but is especially important during the
concept development phase to minimise cost of design changes
☛ Testing

☛ Each design revision or update Other tools that are useful in conjunction with
the FMEA:
☛ Brainstorming
☛ Fault Tree Analysis (FTA)
☛ Risk Management Maintenance Engineering & Management
Introduction
The FMEA process is an on-going, bottom-up approach typically utilised in three
areas of product realization and use, namely design, manufacturing and service.
A design FMEA examines potential product failures and the effects of these
failures to the end user, while a manufacturing or process FMEA examines the
variables that can affect the quality of a process. The aim of a service FMEA is
to prevent the misuse or misrepresentation of the tools and materials used in
servicing a product.
There is not a single, correct method for conducting an FMEA, however the
automotive industry and the U.S. Department of Défense (Mil-Std-1629A) have
standardised procedures/processes within their respective realms. Companies

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Unit-1 ME-VIII SEM Maintenance Management

who have adopted the FMEA process will typically adapt and apply the process
to meet their specific needs. Typically, the main elements of the FMEA are:
• The failure mode that describes the way in which a design fails to perform as
intended or according to specification;
• The effect or the impact on the customer resulting from the failure mode; and
• the cause(s) or means by which an element of the design resulted in a failure
mode.
It is important to note that the relationship between and within failure modes,
effects and causes can be complex. For example, a single cause may have multiple
effects or a combination of causes could result in a single effect. To add further
complexity, causes can result from other causes, and effects can propagate other
effects.
Who Should Complete the FMEA
As with most aspects of design, the best approach to completing an FMEA is
with crossfunctional input. The participants should be drawn from all branches of
the organisation including purchasing, marketing, human factors, safety,
reliability, manufacturing and any other appropriate disciplines. To complete the
FMEA most efficiently, the designer should conduct the FMEA concurrently with
the design process then meet with the crossfunctional group to discuss and obtain
consensus on the failure modes identified and the ratings assigned.
Relationship between Reliability and Safety
Designers often focus on the safety element of a product, erroneously assuming
that this directly translates into a reliable product. If a high safety factor is used
in product design, the result may be an overdesigned, unreliable product that may
not necessarily be able to function as intended. Consider the aerospace industry
that requires safe and reliable products that, by the nature of their function, cannot
be overdesigned.
Application of the Design FMEA
As mentioned previously, there is not one single FMEA method. The following
ten steps provide a basic approach that can be followed in order to conduct a basic
FMEA. An example of a table lamp is used to help illustrate the process.
Attachment 3.2 provides a sample format for completing an FMEA.

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Unit-1 ME-VIII SEM Maintenance Management

UNIT-1 (Introduction to Maintenance Management)

Failure Analysis
LECTURE NO:-6

Step 1: Identify components and associated functions

The first step of an FMEA is to identify all of the components to be evaluated.
This may Maintenance Engineering & Management (Module-3) 9 include all of
the parts that constitute the product or, if the focus is only part of a product, the
parts that make up the applicable sub-assemblies. The function(s) of each part
within in the product are briefly described.
Example:
Part Description Part Function
Light bulb Provides x ± y lux of illumination
Plug 2 wire electrical plug
Cord Conducts power from outlet to lamp
Step 2: Identify failure modes
The potential failure mode(s) for each part are identified. Failure modes can
include but are not limited to:
It is important to consider that a part may have more than one mode of failure.
Example:
Part Description Failure Mode
Cord Short circuit
Open circuit
Insulation failure
Step 3: Identify effects of the failure modes
For each failure mode identified, the consequences or effects on product, property
and people are listed. These effects are best described as seen though the eyes of
the customer.

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Unit-1 ME-VIII SEM Maintenance Management

Example:
Failure Mode Failure Effects
Short No light/ Electrical fire/ Blown fuse
Insulation fail Shock/injury hazard
Step 4: Determine severity of the failure mode
The severity or criticality rating indicates how significant of an impact the effect
is on the customer. Severity can range from insignificant to risk of fatality.
Depending on the FMEA method employed, severity is usually given either a
numeric rating or a coded rating. The advantage of a numeric rating is the ability
to be able to calculate the Risk Priority Number (RPN) (see Step 9). Severity
ratings can be customised as long as they are well defined, documented and
applied consistently. Attachment 3.3 provides examples of severity ratings.
Example:
Failure Effects Severity No light 8-Very high Shock/injury hazard 10-Hazardous-
no warning Maintenance Engineering & Management (Module-3) 10
Step 5: Identify cause(s) of the failure mode For each mode of failure, causes are
identified. These causes can be design deficiencies that result in performance
failures, or induce manufacturing errors.
Example:
Failure Mode Cause Insulation failure Cord pinched
Step 6: Determine probability of occurrence
This step involves determining or estimating the probability that a given cause or
failure mode will occur. The probability of occurrence can be determined from
field data or history of previous products. If this information is not available, a
subjective rating is made based on the experience and knowledge of the cross-
functional experts. Two of the methods used for rating the probability of
occurrence are a numeric ranking and a relative probability of failure. Attachment
C provides an example of a numeric ranking. As with a numeric severity rating,
a numeric probability of occurrence rating can be used in calculating the RPN. If
a relative scale is used, each failure mode is judged against the other failure
modes. High, moderate, low and unlikely are ratings that can be used. As with
severity ratings, probability of occurrence ratings can be customised if they are
well defined, documented and used consistently.
Example: Cause Prob. Of Occurrence Cord pinched 2-Low (few failures)
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Unit-1 ME-VIII SEM Maintenance Management

UNIT-1 (Introduction to Maintenance Management)

Failure Analysis Cont.
LECTURE NO:-7&8

Step 7: Identify controls Identify the controls that are currently in place that either
prevent or detect the cause of the failure mode.
Preventative controls either eliminate the cause or reduce the rate of occurrence.
Controls that detect the cause allow for corrective action while controls that detect
failure allow for interception of the product before it reaches subsequent
operations or the customer.
Example:
Cause Current controls Cord pinched Review CSA standards Warranty data from
preceding products
Step 8: Determine effectiveness of current controls
The control effectiveness rating estimates how well the cause or failure mode can
be prevented or detected. If more than one control is used for a given cause or
failure mode, an effectiveness rating is given to the group of controls. Control
effectiveness ratings can be customised provided the guidelines as previously
outlined for severity and occurrence are followed. Attachment 3.5 provides
example ratings.
Example:
Current controls Control effectiveness Review CSA standards 5-Moderate
Warranty data from preceding products Maintenance Engineering &
Management (Module-3) 11
Step 9: Calculate Risk Priority Number (RPN)
The RPN is an optional step that can be used to help prioritise failure modes for
action. It is calculated for each failure mode by multiplying the numerical ratings
of the severity, probability of occurrence and the probability of detection
(effectiveness of detection controls) (RPN=S x O x D). In general, the failure
modes that have the greatest RPN receive priority for corrective action. The RPN
should not firmly dictate priority as some failure modes may warrant immediate
action although their RPN may not rank among the highest.

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Unit-1 ME-VIII SEM Maintenance Management

Step 10: Determine actions to reduce risk of failure mode

Taking action to reduce risk of failure is the most crucial aspect of an FMEA. The
FMEA should be reviewed to determine where corrective action should be taken,
as well as what action should be taken and when. Some failure modes will be
identified for immediate action while others will be scheduled with targeted
completion dates. Conversely, some failure modes may not receive any attention
or be scheduled to be reassessed at a later date. -Actions to resolve failures may
take the form of design improvements, changes in component selection, the
inclusion of redundancy in the design, or incorporation design for safety aspects.
Regardless of the recommended action, all should be documented, assigned and
followed to completion. The following attachments are given to guide the filling
of FMEA form as follows :
Attachment
Maintenance Engineering & Management
Benefits of conducting FMEA
• Increase customer satisfaction by improving safety and reliability and
mitigating the adverse effect of problems before they reach the customer.
• Improve development efficiency in terms of time and cost by solving reliability
and manufacturing problems during design stages. The more we move in the
development stage, the more rectifying problems becomes more expensive.
• Document, prioritize, and communicate potential risks by making issues
explicit to FMEA team members, management, and customers.
• Help reduce the chances of catastrophic failure that can result in injuries and/or
adverse effect on the environment.
• Optimize maintenance efforts by suggesting applicable and effective
preventive maintenance tasks for potential failure modes.
FMEA Applications
Although FMEA started in the aerospace and automobile industry, it found
application in various areas, such as the healthcare industry. With patient safety
a priority in healthcare, the technique has seen application in healthcare. Medical
devices and medical services such as drug delivery have added FMEA as a means
to understand the risks not considered by individual design and process personnel.
FMEA allows a team of persons to review the design at key points in product
development or medical service and make comments and changes to the design
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Unit-1 ME-VIII SEM Maintenance Management

of the product or process well in advance of actually experiencing the failure. The
Food and Drug Administration (FDA) has recognized FMEA as a design
verification method for Drugs and Medical Devices. Hospitals also use FMEA to
prevent the possibility of process errors and mistakes leading to incorrect surgery
or medication administration errors. FMEA is now an integral part of many
hospitals’ continuous improvement program. Maintenance Engineering & Manag

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Notes By: -Shekhar Kaushik (Assistant Professor-ME Department, MITRC)