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Maintenance, Maintenance planning , & Maintenance activity for machine tools

Maintenance
Maintenance can be defined as a combination of actions carried out to replace, repair, service the components. Some identifiable grouping of components in a manufacturing plant, so that it will continue to operate at a specified availability for a specified time.

Objective of maintenance
Ensure safety. To keep the life of the equipment. Minimum breakdown time. Utilization of optimum capacity. To ensure highest availability. To modify the machine tools and other production facilities. Economy. Improve productivity.

Policies
Policy helps to work in line with the objectives. Polices take the form of general statement to lead managerial activity through proper channel towards the objectives.

Maintenance policies
Emphasize maintenances. Provide extra machines replace machine parts early. Involve operators in maintenance . Overdesign machines. Increase spare parts supply. Enhance maintenance dept. capability. Special training programs to maintain workers skill level.

Types of Maintenance
Maintenance

Corrective

Scheduled

Preventive

Proactive

Break down maintenance


Break down maintenance implies that repairs are made after the equipment fails to perform its normal function.

Scheduled maintenance
This system provide for inspection , overhaul, lubrication and servicing of certain machines at pre determined dates. This type of maintenance utilizes the idle time of equipment without much disturbance in production schedule.

Preventive maintenance
In preventive maintenance periodic inspection is carried out to anticipate breakdown and to prevent them before they occur, instead of allowing the breakdown to happen and then to take action. The objective of preventive maintenance is to prevent breakdown and to ensure operational accuracy and safety.

Elements in preventive maintenance


Inspection. Overhaul. Lubrication. Planning and scheduling. Record and analysis. Training to maintenance staff. Storage of spare parts.

Proactive
Proactive maintenance is a maintenance strategy for stabilizing the reliability of machines or equipment. Its central theme involves directing corrective actions aimed at failure root causes, not active failure symptoms, faults or machine wear conditions.

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Organization setup
A sound organizational setup is necessary for effective administration of maintenance activities.
Work manager
Facilities foreman Shop maintenance

Maintenance department
The organization setup depends upon: Type of maintenance activities to be carried out. Continuity of operations. Size of the plant.

Maintenance planning
The maintenance action, which is carried out with some pre thoughts, prior planning, record keeping and control actions, is called a planned maintenance. Problem -> cause -> diagnosis-> rectification.

Maintenance procedure
Identifying the machines. Method of maintenance. Maintenance cost. Control action.

Maintenance scheduling
Maintenance scheduling is a comprehensive list of all maintenance action and their methods and time of their execution. While preparing maintenance schedule for a particular machine or equipment, it is essential to refer manufactures drawing technical data and workshop manuals.

Equipment's records
Name of the equipment Supplier Order no Date of commissioning Cost Drawing no of supplier -

Repair cycle
The period that elapses from the time the item is removed in a reparable condition to the time it is returned to stock in a serviceable condition.

Repair complexity

Equipment history card

Master schedule card

Work order

Work report
After maintenance the next step is the preparation of maintenance report. It provide the information about maintenance of equipment, person who involved in the maintenance, time taken, maintenance cost, inspection.

Reliability
Reliability is the probability of performing, without failure, specified function under given conditions for a specified period of time.

Spare parts planning


Spare parts planning is a process to ensure the effective utilization of the parts which is to be replaced. Needs To ensure regular production. To take advantage of price. To facilitate maintenance planning & scheduling.

Factors to be considered for spare planning

Long term or short term required. Past experience, spare parts register. Cost of the parts, cost of storage and handling. Availability. Quality.

Codification of spares
Codification is primarily for unique identification of the items in an inventory, this unique identification has its own stream of benefits.it is of particular importance in the case of spares, because as opposed to regular items in inventory the spare comes in different varieties.

Preservation of past data


Each and every replacement of spares should be recorded in a card for an individual machine or instrument. The cause of breakdown ,the spare replaced, the cost of the spare etc, should be recorded clearly. Such data card will ultimately provide information to quantify the average requirement of spares.

Practice to use standard spares


It is always recommended to purchase standard spares. Such a practice assures the reliability of fitting and operation and on the other hand easy procurement is also ensured.

Purchase procedure
Recognition of the need. Selection of source of supply. Inviting quotation. Processing the quotation. Placing the order and follow up. Receipt and inspection Approval of payment.

Classification of spare parts


Break down spares

Insurance spares

Capital spares

Routable spares

Breakdown spares
These are the spares which are required in large quantities at more or less frequent periodic intervals as and when the breakdown occur.

Insurance spares
As the name indicates, the purpose of these spares is to provide an insurance against the relatively remotely possible breakdown or failure of an equipment/component will survive the life time of the machinery or plant is quite high. Such spares has been observed to be as high as 95 to 99% over the life span of the machinery.

Capital spares
These are also high reliability spares, but not as the insurance spares. The reliability is not as low as that of the maintenance spares as well. Moreover these spares have relatively higher purchase cost than spares is usually made at the time of purchase of the capital equipment itself.

Routable spares
These are the reusable spare parts, which after their breakdown can be reconditioned and rescued. Typical examples are the step any in the car, jet engine in aircraft, tyre tubes in cycles, electrical motors etc. since these have more than one life, the cycle of their various lives needs to be taken into consideration in the analysis of their inventory policy.

ABC analysis
Always Better Control analysis or alphabetical approach ABC analysis divides inventories into three grouping in terms of percentage of numbers of items and percentage of total value.

In ABC analysis is important items (high usage valued items) are grouped in A items.
while trivial items (low usage items are grouped in C items). Remaining middle level items are considered B items.

The items classified by virtue of their uses as

Category
A high value items

% of items 10%
20% 70%

Amount 70%
20% 10%

B medium value items

C low value items

Steps in ABC analysis


Calculate annual usage of each item in terms of rupees. Rank the items from highest annual usage in rupees to lowest annual usage in rupees. Compute the total value. Find the % of high , middle, low valued items.

Application
To keep capital tied up in inventories as low as practicable. To ensure that all the materials would be available when required.

ABC analysis can be effectively used in material management.

Utilization of human resources in maintenance The maintenance planning succeeds often with the perfect utilization human resources. Utilization of human resources intend right job for right person. Practice of maintenance carried out by the operators themselves, while engaged in production. This will ultimately minimize the workload of the maintenance department. This will come in to effective only when proper training provide to the individuals.

Work measurement maintenance organization

Work maintenance is application of technique designed to establish the time for a qualified worker to carry out a specified job at a defined level of performance. Measurement of work is equally important in the production as well as maintenance planning.

Work measurement techniques


Job estimating. Time study technique. Statistical analysis. Work sampling. Analytical procedure. Method time measurement.

Job estimating
Through experienced mental approximation experienced and knowledgeable person.

Time study
The first step is to break the maintenance job into number of elements. Time is to be recorded for each element separately with the help of a stop watch.

Statistical analysis
The total time spent for a definite type of maintenance work over a period of time is divided by the number of times the work has been done. The average time, thus calculated is taken as standard.

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