Transcript TAM: Chapter 01

CHAPTER 1
MAINTENANCE
“Act of causing to continue ”
[New Oxford Dictionary]
TRADITIONAL DEFINITION :
• “The combination of all technical and associated actions intended to retain
an item in, or, restore it to a state in which it can
perform its required function”.
CURRENT DEFINITION :
• “All actions that are carried out to safeguard the technical integrity of
an asset and to ensure its availability such that maximum cash returns
can be realized from the asset thereby enhancing the value of the asset”.
ROLE OF MAINTENANCE
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Preserve and prolong the working life of plant and equipment.
Upkeep and protection of plant, buildings, machinery and other fixed assets.
Safeguard investment by minimising deterioration.
Keep the assets in efficient working condition.
Ensure reliability of plant and equipment.
Minimise idle time and loss of production.
Maximise efficiency through optimum use of facilities.
Generate a safe and healthy, working environment and maintain
safety consciousness.
Minimise maintenance cost.
Improve performance of plant and machinery.
Keep abreast of latest maintenance techniques and achieve excellence to meet the
new challenges.
NEED FOR MAINTENANCE
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To
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keep assets in top condition.
avoid failures.
minimize hazardous situations.
correct deterioration.
modify plants.
generate safe working conditions.
obtain on grade products.
increase productivity.
reduce wastage of material & parts.
reduce manufacturing cost.
add in high quality & economical operation.
Maintenance is a key element in the organisation’s
value chain
BUSINESS
OBJECTIVES
INCREASE
RESERVES
INCREASES
CASH
MARGIN
REDUCES
OPERATING
COSTS
COST EFFECTIVE MAINTENANCE
INCREASES
SALES
AND REVENUE
INCREASES
PRODUCTION
HIGH
FACILITY
AVAILABILITY
TYPES OF MAINTENANCE
BREAKDOWN MAINTENANCE
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This is a PANIC or CRISIS maintenance
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It is not desired at all in today's environment
TYPES OF MAINTENANCE
BREAKDOWN MAINTENANCE
• BATH TUB CURVE
– Infantile Deaths
– Wear-out Stage
– Abnormal Operations
• DISADVANTAGES
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Uncertain - Occurrence & Repairs
Uncertain Production
Costly Repairs
Unsafe Situation
TYPES OF MAINTENANCE
PREVENTIVE MAINTENANCE
This is a systematic and planned attention, monitoring and analysis.
It is most effective if there is strong age related failure mode.
The guiding principle is “Prevention is better than cure”
Objectives of Preventive Maintenance are
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Retard process of deterioration and wear
Asses extent of deterioration
Action to restore original capacity
Improve reliability and maintainability of equipment thus eliminating
breakdown
TYPES OF MAINTENANCE
PREVENTIVE MAINTENANCE EXAMPLES
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Visual External Inspection
Lubrication Replenishments
Strainer Cleaning
Painting
Adjusting Belt Tension
Preventive Maintenance Programme
TYPES OF MAINTENANCE
ADVANTAGE OF PREVENTIVE MAINTENANCE
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Less down time
Fewer repetitive repairs
Lower repair cost than breakdown repair cost
Superior quality control
Increased life of plant and equipment
Need of standby equipment reduced
Reduction in maintenance cost
Leveled workload and workforce
Better spares control
Enhanced safe working conditions
Increase in production
TYPES OF MAINTENANCE
PREDICTIVE MAINTENANCE
By predictive maintenance equipment condition can be known during
normal operation through :
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Online monitoring, measurements, ND testing, etc.
Health of equipment can be predicted with certainty and necessary
corrective actions generated
The result of predictive maintenance can be extrapolated to determine
useful residual life
Leading to prediction of approximate date of failure
TYPES OF MAINTENANCE
PREDICTIVE MAINTENANCE EXAMPLES
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Ultrasonic thickness measurements
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On-line vibration measurements
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Measurement program
Testing lubricating oil / hydraulic oil
TYPES OF MAINTENANCE
POPULAR PREDICTIVE MAINTEANCE TECHNOLOGY
TECHNOLOGY
APPLICATIONS
Iodic vibration analysis
All rotary equipment
• Vibration analysis
• On-line vibration analysis
• Oil sample analysis
• Thermography
• Motor stator analysis & elect.
• - Surge testing
• Motor current signature analysis
• Air borne ultrasonics
• Pulse-echo ultrasonics
• Process parameters
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All rotary equipment
Critical rotary equipment
Critical & low speed equipment
Electrical components,insulation
Motor stator and insulation
Break down
Motor rotor bars, eccentricity
Steam traps, vacuum leaks
Pipe and vessel thickness
Process or mechanical
Degradation
TYPES OF MAINTENANCE
PROACTIVE MAINTENANCE
Proactive Maintenance emphasizes on
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Root Cause Failure Analysis
Precision repairs and installation
Training of maintenance and operational personnel
Review and correct purchase specification
Proactive maintenance is easily integrated with predictive
maintenance and completes the platform needed for Reliability
Centered Maintenance program
TYPES OF MAINTENANCE
ADVANTAGES OF PROACTIVE MAINTENANCE
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Repetitive problems that shorten component life are identified and
designed out
This can include standards placed on suppliers for performance
acceptability of their products/services, and verification that these are
met
Assuring that equipment installation is done to precision standards
(Balancing, Aligning) leading to extended life
Factors limiting component life are identified and eliminated
Reliability centered maintenance program
TYPES OF MAINTENANCE
BREAKDOWN
MAINTENANCE
PREVENTIVE
MAINTENANCE
PREDICTIVE
MAINTENANCE
RELIABILITY CENTERED
MAINTENANCE
ROOT CAUSE
FAILURE
ANALYSIS
PROACTIVE
MAINTENANCE