MAINTENANCE MANAGEMENT

BY

SHEREEN SHAHANA & MARY JASMINE D

WHAT IS MAINTENANCE? MAINTENANCE IS THE PROCESS OF

KEEPING MACHINE AND EQUIPMENT IN GOOD WORKING CONDITION SO THAT THE EFFICIENCY IS RETAINED AND ITS LIFE IS INCREASED.

IT’S A COMBINATION OF ACTIONS CARRIED OUT BY AN ORGANIZATION TO REPLACE,REPAIR,SERVICE THE MACHINES,COMPONENTS OR THEIR GROUPS IN A MANUFACTURING PLANT,SO THAT IT WILL CONTINUE TO OPERATE SATISFACTORILY.

FUNCTIONS OF MAINTENANCEa) INSPECTIONb) REPAIRc) OVERHAULd) LUBRICATIONe) SALVAGE

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 REPARING THE

COMPONENT OR REPLACING THE ITEM OR PART BY ANOTHER ITEM TO RESTORE FAILED OR BROKEN DOWN ITEM IN WORKING ORDER.

OVERHAUL FALLS UNDER PREVENTVE MAINTENANCE . FREQUENCY OF OVERHAULING IS LESS THAN

LUBRICATION AND INSPECTION. HERE THE MACHINE IS STRIPPEDAND 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 ITSELF. LUBRICATION CAN BE

DAILY,WEEKLY,FORTNIGHTLY,MONTHLY.

MAINTENANCE PRACTICES DIFFERENT MAINTENANCE PRATICES

ARE ADOPTED TO SUIT THE VARIOUS TYPES OF PRODUCTION MACHINERIES AND OTHER DEVICES.THEY ARE:-

I. BREAKDOWN MAINTENANCEII. PREVENTIVE MAINTENANCEIII. SCHEDULED MAINTENANCEIV. PRODUCTIVE MAINTENANCE

1.BREAK DOWN MAINTENANCE MACHINES ARE ALLOWED TO RUN

WITHOUT CARRYING OUT ANY MAINTENANCE.

ONLY WHEN IT BECOMES OUT OF ORDER(STOP WORKING) IT IS REPAIRED

NEXT MAINTENANCE IS DONE ONLY WHEN IT BREAKS DOWN.

APPLICABLE TO MACHINES WHICH ARE NOT IMPORTANT i.e; BREAK DOWN OF THESE MACHINES WILL NOT AFFECT THE PRODUCTION PROCESS

CAUSES OF BREAKDOWN:

I. FAILURE TO REPLACE THE WORNOUT PARTS

II. NON APPLICATION OF LUBRICANTSIII. NEGLECTED COOLING SYSTEMIV. CARELESSNESS TOWARDS MINOR

REPAIRS.

2.PREVENTIVE MAINTENANCE AIMED AT AVOIDING OR PREVENTING

BREAKDOWNS. THE PRINCIPLE OF PREVENTIVE

MAINTENANCE IS ‘PREVENTION IS BETTER THAN CURE’

HERE SOME COMPONENTS ARE IDENTIFIED AS WEAK SPOTS IN ALL MACHINERIES AND EQUIPMENTS.

THESE PARTS ARE INSPECTED REGULARLY. MINORS REPAIRS ARE CARRIED OUT

IMMEDIATELY AS SOON AS THERE IS NECESSITY AVOIDING UNANTICIPATED BREAKDOWNS.

3.SCHEDULED MAINTENANCE MAINTENANCE DONE ACCORDING TO

RECOMMENDATIONOF THE SUPPLIER OF THE EQUIPMENT.

DONE AT PREDETERMINED DATES. Eg. OVERHAULING OF

MACHINES,CLEANING OF TANKS,ANNUAL SHUT DOWN AND MAINTENANCE OF POWER PLANTS etc..

IN THIS PLANT IS SHUTDOWN NAD FOLLOWING ARE DONE:

o INSPECTION,REPAIRING AND REPLACING OF WORN OUT PARTS.

PRODCUTIVE MAINTENANCE TYPE OF PREVENTIVE MAINTENANCE. IT IS DONE ONLY FOR CRITICAL MACHINERIES. Eg. IN A CHEMICAL PLANT A SMALL PUMP FOR

CIRCULATING CHEMICALS MAY BE A CRITICAL EQUIPMENT IF THE PUMP FAILS TO FUNCTION THEN THE WHOLE PLANT HAVE TO BE STOPPED.SO THE PUMP IS CONSIDERED TO BE A CRITICAL EQUIPMENT IN THE CHEMICAL PLANT.THIS PUMP WHICH IS IDENTIFIED AS A CRITICAL EQUIPMENT SHOULD BE GIVEN PREVENTIVE MAINTENANCE.

ADVANTAGES OF MAINTENANCE

LIFE OF MACHINERY AND EQUIPMENS 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 POSTION.SO PRODUCTION TIME IS WASTED.THIS WILL INCREASE COST OF PRODUCTION.

POOR MAINTENACE CAUSE ACCIDENTS. DUE TO POOR MAINTENACE LIFE OF

MACHINE IS REDUCED.

Thank you..