Breakdown of one piece of equipment or component can hinder the
performance of the entire production process, resulting in
delays.Repairing a machine can be expensive once it break
downMalfunctioning equipment may affect the quality of products.
Scrap or wastage due to such equipment increases the production
costs.During machine breakdown, workers become idle resulting in
higher labor cost per unit of the product.Machine failure can even
lead to accidents in some cases.
Objectives of Plant Maintenance
To maintain the machinery without any breakdown and to keep the
plant in good working condition.To maintain the machinery and other
facilities in good condition so that the maximum capacity can be
operated without any interruption or hindrance.
Objectives of Plant Maintenance
Proper and periodic maintenance ensures the availability of the
machines, buildings and services required by various departments of
the factory for the performance of their functions at optimum
level.
Importance of Maintenance
Plant maintenance has to be given primary consideration in
production management because plant breakdown may cause the
following problems.Production time will lostProduction has to be
rescheduledMore waste material due to sudden stoppage of
processFailure to recover overheadsMost over-time workResorting to
more subcontracting workTemporary work shortages
Duties and Responsibilities of Maintenance Department
It is organised and carried out with forethought, control and
records. It implies all means of examination of all means of
repairing, lubricating, servicing and overhauling in order to
ensure minimum down time in the long run.
Planned maintenance intention is to carry out maintenance
before it is actually needed.
Breakdown Maintenance (Corrective)
Under breakdown maintenance the repairs are undertaken after the
equipment went out of order and it cannot function any longer. The
production department informs the maintenance department to rectify
the defect who find out and correct the repairs.
Scheduled Maintenance
Scheduled maintenance avoids breakdowns. It involves inspection,
lubrication, repair and overhaul of certain equipments which if
neglected can result in breakdown.
Preventive Maintenance
Preventive maintenance is a planned and scheduled system that tries
to minimize the problems of breakdown maintenance.
Predictive Maintenance
It is a latest maintenance technique. It involves application of
human senses or other sensitive instruments likeAudio
GaugesVibration AnalysersAmplitude metersPressure, temperature and
resistance strain gauges
Preventive Maintenance
It is based on prevention is better than cure .The main purpose of
preventive maintenance is to locate the sources of repair and to
remove them before the breakdown occurs. It is undertaken on
scheduled basis for retaining an equipment in a satisfactory
operating condition. It includes periodic test, monitoring,
servicing and inspection.
Preventive Maintenance Program consists following activities
Design and installation of equipmentContinuous monitoring of plant
and inspection of equipment to prevent break down before they
occur.Repeated servicing, up keep and overhaul of
equipment.Adequate lubrication, cleaning and painting of
equipment
Important factors
Analyzing recordsAvailability of skilled peopleLocation of
maintenance facilityPlanning and schedulingApplication of work
standardsEffective Inventory Control Total No. of EquipmentsService
Life of PartsJob ConditionsSources of SupplyDelivery
PeriodEfficiency of the purchasing department
Advantages of Good Preventive Maintenance Program
The production down time will be lessThe overtime pay will be very
low for maintenance personnel on ordinary repairs and adjustments
than breakdown repairs.We can keep less equipment needed in stand
by and reduce the investmentIt reduces product rejects, wastages
and ensures better quality controlIt minimizes maintenance costs of
both labor and materials.It provides longer service life of plant
equipment and building. Only required spares have to be maintained
leading to minimum inventory.It provides safety for workers and
protection for the plant leading to minimize accidents.It predicts
major breakdowns.
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