Maintenance Management

Abhinav Kumar
BFT/14/884
Q1) What should be the objectives of maintenance management for successful working of the
maintenance department?

The maintenance systems have all the same end objective:

Mission-ready machinery and equipment at minimum cost.

This end objective can be touched using different ways.

Some systems try to keep working machinery and equipments under the pressure of
production. These systems have as single objective to rapidly restore the equipment to its
operational readiness state using available resources.
Anothers systems have the same main objective but this main objective is associate with
anothers as: improve maintenance operations, reduce the amount and frequency of
maintenance, reduce the effect of complexity, reduce the maintenance skills required,
reduce the amount of supply support, establish optimum frequency and extent of
preventive maintenance to be carried out, improve and ensure maximum utilization of
maintenance facilities, and improve the maintenance organization.
For understanding the most used maintenance systems (fig. 1):
A generic process for maintenance management consists of the following sequential management
steps for successful working of maintenance department:

1. Asset maintenance planning:

- Identify the asset;

- Prioritize the asset according to maintenance strategy;
- Identify its performance requirements according to strategy;
- Evaluate the assets current performance;
- Plan for its maintenance;

Maintenance task analysis determines the specific information and resources for each item that
requires maintenance including:

Description of the maintenance task (with the level of detail required for a skilled
maintenance person);
Frequency of the task (based on a relevant measure such as elapsed time, operating hours,
number of operational cycles or distance);
Number of personnel, skill level and time required to perform the task;
Maintenance procedures for disassembly and reassembly;
Safety procedures to be followed;
Procedures for handling, transportation and disposal of hazardous materials;
Special tools, test equipment and support equipment required;
Spare parts, materials and consumables to be used or replaced;
Observations and measurements to be made;
 Checkout procedures to verify proper operation and successful completion of the
maintenance task.

2. Schedule maintenance operations;

Scheduling for specific maintenance tasks needs to be done with enough time to schedule and
supply the necessary resources. This includes:

Identifying and assigning personnel;

Acquiring materials and spare parts from external sources or inventory;
Ensuring that tools, transportation, lifting and support equipment are available;
Preparing required operating, maintenance, safety and environmental procedures and work
plans;
Identifying and reserving external resources;
Identifying communication resources;
Providing necessary training.
Manage maintenance actions execution (including data gathering and processing);

3. Assess maintenance;

The purpose of maintenance-related measurement is to measure the effectiveness of maintenance

and maintenance support. Measurements related to specific equipment or groups of similar
equipment may include:
Availability, reliability and maintainability;
Downtime or outage time;
Mean time between failure;
Mean repair time;
Time to failure, statistical representation such as Weibull analysis [16];
Planned and unplanned maintenance cost;

Measurement related to general maintenance management may consist of:

Proportion of planned vs unplanned tasks;
Planned work not completed on time;
Variation of resources between planned and actual;
Spare parts availability;
Workforce utilization and skill level;

Assessment of preventive and corrective maintenance tasks can be performed either each time
maintenance is done (such as after a major failure) or on a periodic basis to review overall
performance, e.g. by type of equipment for a certain time period.

4. Ensure continuous improvement;

Improvement in maintenance and maintenance support activities is achieved by management

support, effective processes and communication. Improvement to maintenance and maintenance
support can be achieved by changes in:

Maintenance definition (type, line of maintenance, etc., for the equipment);

Level of maintenance;
 Maintenance procedures;
Skills and training of maintenance and operations personnel;
Spare parts and materials;
Tools and support equipment;
Use of external resources;
Operating procedures and conditions;
Safety and environmental procedures;
Equipment and system design;
Maintainability of the equipment.

A validation process may be needed to ensure that the appropriate corrective or preventive action
has been taken and improvement has been achieved.

5. Consider the possibility of equipment re-design.

Modifications to equipment, whether to improve functionality or maintainability, should result in re-

assessment of maintenance and maintenance support. This may result in changes in maintenance
definition, resources, training and associated documentation.

Documentation issued by manufacturers, such as vendor service bulletins, should be carefully

reviewed for changes to maintenance and maintenance support.

Modifications to a system may result in some spare parts becoming redundant. For this reason care
should be taken not to buy too large a quantity of spares. A modification may also apply to spare
parts in store. A modification may require the provision of new materials and spare parts.
The modification process should be supported by the configuration management system or some
other change management system to ensure that changes to maintenance and maintenance support
resulting from modifications are implemented and recorded through the proper configuration
control procedures.
Modifications should be evaluated to ensure there is no negative impact on maintenance and
maintenance support.

Bathtub Curve

The initial infant mortality period of bathtub curve is characterized by high failure rate followed by a
period of decreasing failure. Many of the failures associated with this region are linked to poor
design, poor installation, or misapplication. The infant mortality period is followed by a nearly
constant failure rate period known as useful life.
 Q2) Show the classification of maintenance system.

Maintenance

Planned Unplanned
Maintenance Maintenance
(PROACTIVE) (Reactive)

Predictive Preventive Corrective

Emergency
Maintenance Maintenance Maintenance

Statistical Based Running Shutdown Deferred Breakdown

Scheduled
Condition Based Remedial Replace
Maintenance

Condition Based Shutdown

Maintenance Corrective

Reliability Based
Maintenance

Reactive Maintenance:

Reactive maintenance is basically the run it till it breaks maintenance mode. No actions or efforts
are taken to maintain the equipment as the designer originally intended to ensure design life is
reached. Studies as recent as the winter of 2000 indicate this is still the predominant mode of
maintenance in the United States. The referenced study breaks down the average maintenance
program as follows:

>55% Reactive

31% Preventive

12% Predictive

2% Other.

Note that more than 55% of maintenance resources and activities of an average facility are still
reactive.
 Preventive Maintenance
Actions performed on a time- or machine-run-based schedule that detect, preclude, or mitigate
degradation of a component or system with the aim of sustaining or extending its useful life through
controlling degradation to an acceptable level.

While preventive maintenance is not the optimum maintenance program, it does have
several advantages over that of a purely reactive program.
By performing the preventive maintenance as the equipment designer envisioned, we will
extend the life of the equipment closer to design. This translates into dollar savings.
Preventive maintenance (lubrication, filter change, etc.) will generally run the equipment
more efficiently resulting in dollar savings. While we will not prevent equipment
catastrophic failures, we will decrease the number of failures.
Minimizing failures translate into maintenance and capital cost savings.
 Predictive Maintenance
Measurements that detect the onset of system degradation (lower functional state), thereby
allowing causal stressors to be eliminated or controlled prior to any significant deterioration in the
component physical state. Results indicate current and future functional capability.

The advantages of predictive maintenance are many. A well-orchestrated predictive

maintenance program will all but eliminate catastrophic equipment failures. We will be
able to schedule maintenance activities to minimize or delete overtime cost. We will be
able to minimize inventory and order parts, as required, well ahead of time to support the
downstream maintenance needs. We can optimize the operation of the equipment,
saving energy cost and increasing plant reliability.

Past studies have estimated that a properly functioning predictive maintenance program
can provide a savings of 8% to 12% over a program utilizing preventive maintenance
alone. Depending on a facilitys reliance on reactive maintenance and material condition,
it could easily recognize savings opportunities exceeding 30% to 40%.

In fact, independent surveys indicate the following industrial average savings resultant
from initiation of a functional predictive maintenance program:

Return on investment: 10 times

Reduction in maintenance costs: 25% to 30%
Elimination of breakdowns: 70% to 75%
Reduction in downtime: 35% to 45%
Increase in production: 20% to 25%.
 Reliability Centered Maintenance
Reliability centered maintenance (RCM) magazine provides the following definition of RCM: a
process used to determine the maintenance requirements of any physical asset in its operating
context.

Basically, RCM methodology deals with some key issues not dealt with by other maintenance
programs. It recognizes that all equipment in a facility is not of equal importance to either the
process or facility safety. It recognizes that equipment design and operation differs and that
different equipment will have a higher probability to undergo failures from different
degradation mechanisms than others. It also approaches the structuring of a maintenance
program recognizing that a facility does not have unlimited financial and personnel resources
and that the use of both need to be prioritized and optimized.
In a nutshell, RCM is a systematic approach to evaluate a facilitys equipment and resources to
best mate the two and result in a high degree of facility reliability and cost-effectiveness.
RCM is highly reliant on predictive maintenance but also recognizes that maintenance
activities on equipment that is inexpensive and unimportant to facility reliability may best be
left to a reactive maintenance approach.
The following maintenance program breakdowns of continually top-performing facilities
would echo the RCM approach to utilize all available maintenance approaches with the
predominant methodology being predictive.
<10% Reactive
25% to 35% Preventive
45% to 55% Predictive.

Because RCM is so heavily weighted in utilization of predictive maintenance technologies, its

program advantages and disadvantages mirror those of predictive maintenance. In addition to these
advantages, RCM will allow a facility to more closely match resources to need while improving
reliability and decreasing cost.
 Q3) A company has machine whose cost is Rs 30000/-. Its maintenance cost and resale value at
end of different years are as given below. At what time interval in your opinion should the
machine be replaced?

Year I II III IV V VI
Maintenance 4500 4700 5000 5500 6500 7500
Cost
Resale Value 27000 25300 24000 21000 18000 1300

Answer:

Here, it is given that,

Cost of machine = 30000 /-

Year I II III IV V VI
Maintenance
4500 4700 5000 5500 6500 7500
Cost
Resale Value 27000 25300 24000 21000 18000 1300

Then,

A B C=30000-B D D E=C+D F=E/A

Cumulative
Resale Maintenance Average
End of Year Capital Loss Maintenance Total Cost
Value Cost Cost
Cost
I 27000 3000 4500 4500 7500 7500
II 25300 4700 4700 9200 13900 6950
III 24000 6000 5000 14200 20200 6733.333
IV 21000 9000 5500 19700 28700 7175
V 18000 12000 6500 26200 38200 7640
VI 1300 28700 7500 33700 62400 10400

Optimum replacement period of the machine is at the end of the year III at 6733.33.
Q4) Following mortality rates have been observed for certain types of fuses. There are 1,000 fuses
in use and it costs Rs 5/ to replace an individual fuse. If all fuses where replaced simultaneously it
would cost Rs1.25/- .it is proposed to replace all fuses at fixed interval of time whether or not they
have burnt out and to continue replacing burnt out fuses as they fail. At what intervals the group
replacement should be made and what is the optimum policy

Week 1 2 3 4 5
% of failing by 5 15 35 75 100
The end of week
Answer:

Here, it is given that,

Total number of fuses= 1000 pc.

Individual Replacement Cost= 5/-
Group Replacement Cost= 5/-

Week 1 2 3 4 5
Percentage of
failing by the 5 15 35 75 100
end of week
Probability 0.05 0.10 0.20 0.40 0.25

And, we know that, average life of a fuse = i x pi, where i is the particular year.

= (1 x 0.05) + (2 x 0.10) + (3 x 0.20) + (4 x 0.40) + (5 x 0.25)

=0.05 + 0.20 + 0.06 + 1.6 + 1.25
=3.7

And, Average failure / week = 1000/3.7

= 271 (270.27)

Cost of individual replacement= 271 x 5

= 1355

Now,

Let No be number of fuse at the end of the week 0, or beginning of week 1 = 1000

Therefore, N1 be number of fuse replaced at the end of week 1,

N 1 = N 0 x P1
= 1000 x 0.05
= 50 pc.
And, N2 be number of fuse replaced at the end of week 2,

N 2 = ( N 0 x P 2 ) + ( N 1 x P0 )
= (1000 x 0.1) + (50 x 0.05)
 =100 + 2.5
=102.5 103 pc.
And, N3 be number of fuse replaced at the end of week 3,

N 3 = ( N 0 x P 3 ) + ( N 1 x P2 ) + ( N 2 x P0 )
= (1000 x 0.2) + (50 x 0.1) + (103x0.05)
=200 + 5 + 5.15
=210.15 211 pc.
And, N4 be number of fuse replaced at the end of week 4,

N 4 = ( N 0 x P 4 ) + ( N 1 x P3 ) + ( N 2 x P2 ) + ( N 3 x P1 )
= (1000 x 0.4) + (50 x 0.2) + (103x0.1) + (211 x 0.05)
=400 + 10 +10.3 + 10.55
=430.755 431 pc.
And, N5 be number of fuse replaced at the end of week 5,

N 5 = ( N 0 x P 5 ) + ( N 1 x P4 ) + ( N 2 x P3 ) + ( N 3 x P 2 ) + ( N 4 x P1 )
= (1000 x 0.25) + (50 x 0.4) + (103x0.2) + (211 x 0.1) + (431 X 0.05)
=250 + 20 + 20.6 + 21.1 +21.55
=333.25 334 pc.

A B C D=B+C E=D/A
Group Replacement Cost of
End of week Replacement Individual Fuse that fail Total Cost Average Cost
Cost during that week
1 1250 50 x 5 = 250 1500 1500
2 1250 (50 +103)x 5 = 765 2015 1007.5
3 1250 (50 +103 + 211)x 5 =1820 3070 1023.33333
(50 +103 + 211 + 431)x 5
4 1250 5225 1306.25
=3975
(50 +103 + 211 + 431 +
5 1250 6895 1379
334)x 5 =5645

Optimum replacement policy is group replacement at the end of 2nd week or in the beginning of
3rd week, and replace fuse that failed during 2nd week, and its average cost will be 1007.5.
Reference:

https://uk.linkedin.com/mpr/mpr/shrinknp_400_400/AAEAAQAAAAAAAALlAAAAJGFjOTA3Z
WMyLTU1ZjMtNGRhNC05NTY3LTE5NmNkNzRmODIwYQ.png
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