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8/12/2019 R&D Maintenance
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MAINTENANCEENGINEERING
Muhammad Sajid
Department of chemical engineering, UOG
Research & development in maintenance
Role of overhauling in maintenance
Expert system in maintenance
Note: Data in this presentation
is taken from different books
and is used only foreducational purpose. Credit
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Research and Development in
Maintenance
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Areas Need Improvements
Influence of maintenance on design andselection of plants.
Use of available information.
Training requirements. Standardization of products.
Spare parts management
Development o maintenance facilities.
Concept of condition based maintenance. Concept of contract maintenance.
Development of indigenous spare parts.
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Areas Need
Improvements(Cont.)
Influence of maintenance on design and
selection of plants.The necessity and importance of maintenance can be decided by the designer,
manufacturer and users in consultation with each other in order to improve theavailability and reliability of equipment/system. The sole aim here should be to keep
the operating and maintenance costs to minimum.
Use of available information.The information available on maintainability, reliability etc. can be used to improve the
performance of the equipment/system
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Areas Need Improvements
(Cont.)
Training requirements.
The time to time training must be imparted to the practicing engineers and technicians
to make full use of the advancements in technology.
Standardization of products.
Efforts should be make for the standardization of the parts/components particularly
when they are imported, so that the users face minimum problems.
Interchangeability of parts must be given due attention to make its use feasible.
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Areas Need Improvements
(Cont.)
Spare parts management
The availability of spare parts is the main concern of the maintenance engineers and
the determination of its quantity is a difficult task. Therefore, efforts should be make
to use the facilities of experts in the field.
Development o maintenance facilities.
The advancement in technology have made the task of the maintenance engineers
more challenging because of the size and the volume of the equipment/system .
For effective working of maintenance groups, special facilities required must be
developed to face the challenges in the field of maintenance.
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Areas Need Improvements
(Cont.)
Concept of condition based maintenance.Attempt should be make to use the modern techniques in the
field of maintenance in the case of costly and sophisticated
equipment/system. This concept is quite new and helpful in
maintaining machinery effectively. Although the initial cost ismore but better availability and safety of the equipment is
assured.
Concept of contract maintenance.
As maintenance is complex in nature and required someexpertise. With regard to specialized system/equipment the
contract maintenance works well since qualified and trained
personnel are engaged in the job. e.g. computer industry
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Areas Need Improvements
(Cont.)
Development of indigenous spare parts.
In case of imported equipments/systems it isdifficult to procure and preserve adequate
quantity of spare parts and therefore effortsshould be made to develop material and spareparts at the organizational level. Sometimesthe manufacturers stop production of a
particular type of equipment the sameequipment is n use. Obsolescence is anotherfactor, which calls for the development oftechnology to meet out the challenges.
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Role of Overhauling
Equipment/systems are of two types
I. Equipment with diminishing efficiency
II. Equipment with constant efficiency
Overhauling of first type of equipments, reduces
its operational costs and extended its life
span.
The period of overhaul must be decided toactually derive the gain of the above concept.
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Expert System in Maintenance
The unexpected equipment failure entail
significant financial losses in manufacturing
system.
In order to avoid unscheduled failure, theconcept of preventive maintenance with expert
system can be used.
An expert system is a program, which has awide base of knowledge in a restricted
domain, and uses complex inferential
reasoning to perform tasks, which human
experts could do.
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Expert System in Maintenance(Cont.)
Knowledge Base:
It encompasses knowledge about the domain
problem. Knowledge representing methods
are production rules, frames, semantic netsand predicate logic.
Inference engine:
The inference engine is the problem solvingcontrol strategy or rule interpreter, which
applies the knowledge in the knowledge base
of the problem. The strategies are forward and
backward chaining.
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External Maintenance
When maintenance within organization is not
possible or maintenance system required
some specific expertise then task given to
external group of experts. This is calledexternal maintenance.
External maintenance is also called
outsourcing.
Many companies such as DESCON, EITMAD
and FFC provide such specific services.
Computer industry is a major outsourcing
industry.
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Logistics
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Finance Management
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Inventory Management
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Effects of Maintenance
Cost effective maintenance will boost theproductivity of the production system.
Optimum maintenance will prolong the life of
equipments/system. Helpful in achieving production target and
continuous plant operation.
Effective maintenance will enhance the
reliability of the system/equipment. Proper maintenance will improve the working
environment
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Maintainability
Maintainability is defined as the probability ofrestoration of a failed device or equipment or
asset to operational effectiveness within a
specified time.
It is associated to the design of assets to be
maintained and is the measure of the ease of
maintenance.
Maintainability is expressed as mean time torepair (MTTR) i.e. how much time is required to
restore the equipment/system to its working
condition
The limitation of maintainability are- it cannot be
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Reliability
It is defined as the probability that an asset or
a system will operate satisfactorily for a pre-
determined period of time, under the working
conditions for which it was designed. Failure Rate (FR) or mean time between
failure (MTBF) is a parameter to express
reliability.
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Principles of Maintenance
Effectiveness of maintenance depends on
systematic conductance of various interrelated
activities. To achieve the overall objectives of a
maintenance system, certain establishedprinciples must be followed. These principles
help guide the maintenance staff in the
efficient discharge of their duties.
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Plant Management in Maintenance
Work
The main role of maintenance function is toprovide safe and effective operation ofproduction equipment in order to achieve thedesired production targets on timeeconomically. Sometimes it is observed thatuntil and unless there is breakdown ofequipment, the production department doesnot follow the maintenance programmebecause of its keenness to accomplish the jobin stipulated time. Therefore it is necessarythat all the departments cooperate with eachother to meet the organizational goals.
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Maintenance Objective Versus
Plant Production
The plant production department is normallyassigned production targets, in the light ofwhich the maintenance team must formulateits assigned objectives to match the totalobjectives of the organization. It is observedthat, in practice, the production departmenttends to overlook the maintenance functions inits eagerness to meet the production targets.Such an attitude may lead to seriouscircumstances, resulting in equipment failuresor accidents. The programme of scheduledmaintenance must be followed.
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Establishment of Work-order and
Recording System
Preparation of work order for maintenance
activity is an important task as it indicates the
nature of the work to be performed and the
series of operations to be followed for aparticular job. It is essential that at every
workstation, proper records/entries be
maintained to monitor the health of the
equipment as well as its lifespan. Presently, inmany organization this task is being performed
with the help of computers.
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Information Based Decision
Making
Effective and reliable information system is
essential for the successful execution of any
activity. Such a system may be used for
decision making in respect of manpower andspare parts requirements there fore data
entries for any type of breakdown must be
properly recorded in time, so that the same
may be utilized as and when required.
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Adherence to Planned
Maintenance System
1. Lack of implementation of manufacturer
instruction during operation/maintenance.
2. Result is unscheduled breakdown
3. Proper implementation of manufacturer
instruction results longer life and safe
operation
4. Proper use of manpower
Pl i f M i
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Planning of Maintenance
Functions
Major jobs must be planned for effective use of
resources.
After breakdown cost analysis and
comparisons must be done. Efficiency analysis of every major maintenance
activity.
Planning of un excepted breakdown/un evenrepairs.
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Manpower for Maintenance
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Work Force Control
As the nature of maintenance work is quite
unpredictable, the cost of maintenance
function can be kept under control only with
proper monitoring of the work force. For this purpose field data must be collected
regularly, accurately and completely.
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Quality and Availability of Spare
Parts
At the time of purchase of an equipment the
manufacturer do supply some spare parts, but
these are usually not sufficient for all types offaults and for whole life of equipments.
It is essential to stock a complete range and scale
of genuine spare parts to sustain the
functionalities of the equipment without safety
hazards.
T i i f M i t
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Training of Maintenance
Workforce
As equipment changing to modern and
sophisticated, the nature of maintenance also
needs changes.
Whenever a new equipment is purchased, themaintenance personnel along with the operating
personnel must be trained.
Supervisory staff also required proper training for
effective supervision and quality of maintenance.
On job training and evaluation of training is also
essential to meet growing challenges of
maintaining sophisticated and delicate
equipments.
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