Upload
tbmari
View
231
Download
0
Embed Size (px)
Citation preview
7/23/2019 ENGG ZC242-L2
1/40
BITSPilaniPilani Campus
ENGG ZC242
Maintenance & SafetyAnil Jindal
Department of Mechanical Engineering
1
7/23/2019 ENGG ZC242-L2
2/40
BITSPilaniPilani Campus
Introduction to Maintenance
SystemsChapter ! "ecture #2
7/23/2019 ENGG ZC242-L2
3/40
BITS Pilani, Pilani Campus
Maintenance Objectives!cope and "enefitsPolicies
Maintenance as "usiness Proposition
Maintenance Philosoph# $#pes of Maintenance !#stems
"earnin$ %'ecti(es
%
7/23/2019 ENGG ZC242-L2
4/40
BITS Pilani, Pilani Campus
Maintenance %'ecti(es
&
Operational' Ma(imum operating efficienc# of plant
' Ma(imum availabilit# of plant
' )igh *ualit# performance
' !afet#
' $o maintain a plant clean + good appearance
' $o e(tend Plant life to the last limit
' $o reduce environmental impact due to machiner# etc
' $o provide service that ill avert all brea-dons at all times at an# cost.
Cost' Minimi/e maintenance e(penditure and ma(imi/e profits
' $o provide activities ith in the limits of budgetar# control
7/23/2019 ENGG ZC242-L2
5/40
BITS Pilani, Pilani Campus
Maintenance Benefits
0
inancial
Organi/ational
$echnical )uman
Customer relations
7/23/2019 ENGG ZC242-L2
6/40
BITS Pilani, Pilani Campus
)inancia* Benefits
2
E(tended Plant 3ife
4ninterrupted production
5mproved 6ualit# of production 7educed production dela#s
7educed cost of repairs
7/23/2019 ENGG ZC242-L2
7/40BITS Pilani, Pilani Campus
%r$ani+ationa* Benefits
8
Co9ordination beteen production and maintenance
Man poer planning
Planning of deliveries
7/23/2019 ENGG ZC242-L2
8/40BITS Pilani, Pilani Campus
Technica* Benefits
:
5mproved e6uipment suitabilit#
"uild up of technical data
5mproved maintenance schedules 5mproved plant condition
7/23/2019 ENGG ZC242-L2
9/40BITS Pilani, Pilani Campus
,uman considerations
Benefits
;
5ncreased !afet#
5mproved )ouse -eeping
3ess friction beteen relationships
7/23/2019 ENGG ZC242-L2
10/40BITS Pilani, Pilani Campus
Customer re*ationship
Benefits
1 house -eeping
7/23/2019 ENGG ZC242-L2
11/40BITS Pilani, Pilani Campus
Maintenance -o*icy
11
!cope and limits of maintenance
$#pe and level of service e(pected
7esponsibilities to management Personal Practices
$rade union contracts
"udget and financial controls
7/23/2019 ENGG ZC242-L2
12/40BITS Pilani, Pilani Campus
Primar# unctions' Maintenance of e(isting plant e6uipment
' Maintenance of e(isting plant buildings and grounds
' E6uipment inspection and lubrication
' 4tilities generation and distribution
' Alterations and ne installations
!econdar# unctions' !tore-eeping
' Plant protection
' ?aste disposal
' !alvage
' 5nsurance
' Other services
Maintenance )unctions
1@
7/23/2019 ENGG ZC242-L2
13/40
7/23/2019 ENGG ZC242-L2
14/40BITS Pilani, Pilani Campus
$he maintenance costs continue to capture the attention
of senior management as the investment as reliabilit# in
assets become increasingl# greater.
5n some companies, maintenance cost is becoming a
larger percentage of total cost.
or e(ample, a compan# recentl# identified maintenance
cost as in e(cess of &< percent of their total cost of
conversion, representing significant scope for
improvement. )ence it is essential to run maintenance as business.
Maintenance as Business
-roposition
1&
7/23/2019 ENGG ZC242-L2
15/40BITS Pilani, Pilani Campus
!ome organi/ations have centrali/ed hich are responsible for allaspects of asset management.
$he responsibilities of these centrali/ed departments includeB
specif#ing, ac6uiring, installing, and commissioning ne plant,
managing spare parts, planning and control of maintenance s#stem
etc.
"ut in most companies engineering is separated from maintenance.
Engineering department loo-s for specification, ac6uisition and
deplo#ment of ne plant, hile the maintenance department loo-s for
all aspects of maintenance after the plant has been commissioned.
$he concept of business unit started to emerge about to decadesago.
The Business 0nit Concept
10
7/23/2019 ENGG ZC242-L2
16/40BITS Pilani, Pilani Campus
Business 0nit Concept
12
$he concept has sub9divided larger underta-ing into businessunits, usuall# centered on specific product or service
Maintenance department is often bro-en up and its personnel
allocated to the business units.
7/23/2019 ENGG ZC242-L2
17/40BITS Pilani, Pilani Campus
)uge leap in automation in last to decades.
$he number of operators have shrun- and the machines
are ta-ing over.
5ncase of some s#stems there are no operators.
Computer programs drive these s#stems ith occasional
additional guidance from people in distant control room.
More machines rep*acin$ men means! more
maintenance acti(ities1
utomation
18
7/23/2019 ENGG ZC242-L2
18/40BITS Pilani, Pilani Campus
!enior e(ecutives thin- that if it ere possible to reducee(penditure on operation, it should be possible to reduce
maintenance cost b# similar amount.
Companies have achieved an increase in production b#
replacing men b# machines and this increases the costof maintenance.
So decrease in operatin$ cost is accompanied y
increase in maintenance cost1
Maintenance manager should be aare of the folloingo !afe minimum to be spent on proactive maintenance
o Conse6uences of not spending enough on maintenance
Maintenance cost reduction
1:
7/23/2019 ENGG ZC242-L2
19/40BITS Pilani, Pilani Campus
Most people thin- of the maintenance function asB
o i(ing things that brea-.
o eeping things loo-ing good.
o eeping things from brea-ing.
"ut for a structured maintenance, the folloing 6uestions
have to be ansered
o 5s it that staff and suppl# are planned onl# to address brea-don
o ?hat is the cost of e6uipment dontime
o )o much time is re6uired for routine maintenance activities
o ?hether focus needs to be on activities to reduce brea-don or allo
things to brea- don
Maintenance -hi*osophy
1;
7/23/2019 ENGG ZC242-L2
20/40BITS Pilani, Pilani Campus
3ifferent Maintenance Systems
@