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0 MAINTENANCE
Electrical safety
Objective
Objectives of Electrical Safety :
Be familiar with the fundamental concepts of electricity.
Be familiar with the effects of electricity on the human body.
Be able to recognize common electrical hazards.
Be familiar with electrical protective devices
IMPORTANCE ELECTRICAL
SAFETY
Safe working environment and operation of electrical installations
Safe use of electricity & electrical equipment
Safety of working personnel-electrical technical person and workers
Safety standards of electrical installations & equipment.
TYPES OF ELECTRICAL
INJURIES
There are four main types of electrical
injuries:
Tidiness
Dispose of sharp objects, blades, glass shards in suitable containers -
Ensure the workshop is tidy.
Machinery
Make sure machinery is properly installed, levelled and are periodically
maintained or serviced.
Electricity regulation 1994
Electricity regulation 1994
Regulation 110. Inspection and test for the
purpose of maintenance of installation, etc.
Personal
Ambient
Insulation Knowledge and
Conditions
experience
Personal
Grounding Mental
Condition
Equipment
Status
Safety Regulations
Insulation
Dielectric strength of the insulation.
Grounding
Electrical equipment should be properly grounded.
Equipment Status
Good condition
Use proper equipment for the job.
Personal Mental Condition
Should not be mentally disturbed.
Personal Knowledge and experience
Should be properly trained for the activity, he has to perform.
Ambient Conditions
The conditions under which the equipment works efficiently.
Current rating, Voltage rating, Frequency, Temperature.
1.0 MAINTENANCE
MAINTENANCE
Maintenance Definition
British Standard Glossary of terms (3811:1993) defined
maintenance as:
the combination of all technical and administrative
actions, including supervision actions, intended to retain
an item in, or restore it to, a state in which it can
perform a required function.
Maintenance Definition
INCREASE OF MAINTAINED
EQUIPMENT
EFFECTIVE PRODUCT
EFFICIENCY MAINTENANCE QUALITY
AVOID IMPROVE
UNNECESSARY OVERALL PLANT
SHUTDOWNS EFFECTIVENESS
PROLONG
SYSTEM
LIFE
Effect Without Maintenance
Lower
Operating
Reduced costs
inventory
Continuous Improved
improvement Maintenance quality
Protective Maintenance
To make sure the machine are in good condition
If the necessary for the repair of damage
Modification Maintenance
Is the equipment according to the current need
Protective Maintenance
Corrective maintenance
Maintenance Shutdown
Predictive maintenance
Maintenance
Unplanned Emergency
maintenance maintenance
Maintenance Management
Maintenance Management is defined as
the organization of maintenance within an
agreed policy.
Maintenance Policy is a statement of
principle used to achieve maintenance
objectives and guide Maintenance
Management decision making.
Maintenance
Management
• types of malfunction
2
Maintenance manager
and technical staff
Maintenance Costs
Maintenance cost include :
Cost to
replace or Losses of
repair output
Breakdown Cost
◦ Maintenance
Commitment
Maintenance Costs
Cost
PM Cost
Breakdown Cost
Maintenance
Commitment
Maintenance Costs
Cost
Total Maintenance Cost
PM Cost
Maintenance
Commitment
Maintenance Costs
Cost
Total Maintenance Cost
PM Cost
Breakdown Cost
Optimal Maintenance
Commitment
Maintenance Organization
Maintenance Hierarchy
Maintenance Manager
Monitor the development and productivity of every unit. Carry
out of supervision based on the report made by the technical
manager.
Technical Manager
Give order to every unit based on order of maintenance
manager. Solve any problems from any unit before the problems
will be referred to maintenance manager
Site Support
Contact suppliers or contractor if there maintenance which
required of special expertise. Are going to act of service
employee unable to overcome problems.
Reason maintenance department need get help the outside
maintenance team
Maintenance Versus
Organization Objectives
A system is a collection of components that work
together towards a common objective.
Maintenance can be considered as a system with a
set of activities carried out in parallel with
production systems. A diagrammatic relationship
among organizational objectives, the production
process, and maintenance is shown in Figure 1.1
V ariations in
Maintenance
Demand
PLANNING ORGANIZING
Job Design
Maintenance Philosophy
Standards
Maintenance Load Forecasting
INPUT Maintenance Capacity
Work Measurement OUTPUT
Maintenance Organization
Maintenance Project Management
Facilities
Maintenance Scheduling
Process MONITOR
Operational
Labor Machines
Equipment &
Spares Equipment
Management
* Scheduling
FEEDBACK
CONTROL
Work control
Material control
Inventory control
Cost control
Managing for quality
Maintenance System Output
Amaintenance system can be viewed
as a simple input output model. The
inputs to such a model are labor,
management, tools, spares,
equipment, etc. and the output is
equipment that is up, reliable and well
configured to achieve the planned
operation of the plant.
Maintenance Planning
activities
Planning activities generally include the
following :
1. Maintenance philosophy
2. Maintenance load forecasting
3. Maintenance capacity
4. Maintenance organization
5. Maintenance scheduling.
MAINTENANCE STRATEGIES
(MAINTENANCE FORM)
1.Breakdown Maintenance (Run To Failure)
2. Fault Finding (FF)
3. Time directed Preventive Maintenance(TD)
4. Condition Based Maintenance (CBD)
5. Design Modification (DM)
6. Replacement Instead of Maintenance
7. Planned Replacement (Car Fleet)
8. Opportunity Maintenance
Maintenance Load Forecasting
Maintenance load is a random variable and
forecasting is the process by which maintenance
load is predicted. Load forecasting is essential for
capacity planning. Many factors affect the load,
they include equipment age, climate, quality of
maintenance, etc.
Information on most recent
maintenance load demand and
backlog of maintenance work
Maintenance
load forecasting
Output of
maintenance system
Maintenance Scheduling
Maintenance scheduling is the process of assigning
resources and manpower for jobs to be
accomplished at certain times. It is necessary to
ensure that the needed craftsmen, the parts, and
materials required are available before a
maintenance task can be scheduled.
Maintenance Capacity
Planning
Maintenance capacity planning determines the
resources needed to meet the demand for
maintenance work. Those resources include
manpower, material, spare parts, equipment, and
tools. Critical aspects of maintenance capacity are
the numbers and skills of craftsmen, required
maintenance tools, etc.
Maintenance Organization
Maintenance Organization Depends On
Maintenance Load, Plant Size, Trade and Skill,
Maintenance Could Be Centralized Or Decentralized
Or A Combination of Both. See Figure 1.5 In Text
Book
Production
area A
Maintenance Overload
for production
area A
Production
area B
Maintenance
Overload Central
for production
maintenance
area B
unit
Overload
Production
area C Outside
contractor
help
Maintenance Overload
for production
area C
Organizing Activities
1. Job Design
2. Standard Time
3. Project Management
Job Design
Job design, as related to maintenance work,
comprises the work content of each job and deter-
mines the method that is to be used, special tools
needed, and the skilled persons required.
Time Standards
Time Standards are Needed For Effective Planning.
It is The Time That Takes A Qualified Worker
Worker At 100% Pace To Complete The Job.
Techniques Used For Developing Time standards
Are Work Measurement, Work Sampling.
Estimation and Slotting
Project Management
Techniques Such As CPM, PERT Are Needed For
Large Jobs Such as Overhauls.
They will Enable Better Control OF Cost and work.
They Usually Results In Better Utilization Of
Resources
Control activities
Control is an essential part of Scientific
management. control as applied to maintenance
includes:
1. Work control
2. Inventory control
3. Cost control
4. Quality control
Work Control
The management and control of the maintenance
work is essential for achieving set plans. The work
order system is the tool used for controlling the
maintenance work. A well designed work order
with a sound reporting system is the heart of the
maintenance system The essential tools for
effective control of the maintenance work including
the design of a work order are covered in chapter
2.
Inventory Control
Material and spare parts are essential for
maintenance work. Prior to scheduling
maintenance work spare parts must be available.
Techniques for inventory control are covered in
chapter 7 of the text
MAINTENANCE COSTS.
1. DIRECT COSTS
◦ Cost of Periodic Inspection
◦ Service Cost
◦ Repair Cost, Overhaul Cost
2. STAND-BY COSTS
◦ Cost of Operating and Maintaining a Standby Unit
MAINTENANCE COSTS.
3. LOST PRODUCTION COSTS :
◦ Cost due to Equipment down time.
4. DEGRADATION COST
◦ Cost occurring due to deterioration of the life span of equipment due to no
maintenance or inadequate maintenance.
Cost Control
The control of maintenance cost optimizes all the
costs in maintenance, while achieving, set
organizational objectives such as: availability,
“Quality Rate”, and other efficiency and
effectiveness measures. Cost reduction and control
can be used as an edge for competition in providing
products and services. The issues related to cost
and its control are presented in chapters 2 and 10
Quality Control
In the case of maintenance work "doing it right the
first time" is very essential. Quality may be
assessed as the percentage of accepted
maintenance jobs according to the standard
adopted by the organization. High Quality is usually
assured by checking the critical maintenance jobs
or by maintenance supervision. The details of
maintenance quality control are presented in
chapter 8.
Managing For Quality and
Training
Managing for quality is a managerial responsibility..
The key for managing for quality lies first in the
awareness of the need to improve and second in
selecting appropriate improvement techniques.
Chapter 12 focuses on the aspects of continuous
improvement.
Human Behavior
Managers should try to know how the behavior of
subordinates can affect management's planning,
organizing, and controlling actions. In maintenance
decision making, behavior of subordinates should
be of interest to management. It should be ensured
that the desired level of craftsmen satisfaction is
achieved and maintained.
Maintenance Terms
Availability: The ability of an equipment to
successfully perform its required function at
a stated instant of time or over a stated
period of time.