Session 9

MAINTENANCE
MANAGEMENT

Aneeel_reddy@yahoo.com
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Maintenance:
 “that function of production management that is
concerned with the day-to-day problem of keeping
the physical plant in good operating condition”
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Maintenance Management:


► Maintenance Management is concerned with the

direction and organization of resources
in order to control the availability and
performance of the industrial plants to
some specified level.
► It is a function supporting production
function and is entrusted with the task
of keeping the machinary, equipment and
plant services in proper working
condition.
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Maintenance covers two broad categories:



1. Primary functions
2. Secondary functions
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 Primary functions:
1. Maintenance of existing plant and equipments
2. Maintenance of existing plant buildings and
grounds
3. Equipment Inspection and lubrication
4. Utilities generation and distribution
5. Alterations to existing equipments and
buildings
6. New installations of equipments and
buildings
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 Secondary functions:
1. Storekeeping (keeping stock of spare parts)
2. Plant protection including fire protection
3. Waste disposal
4. Salvage
5. Insurance administration (against fire,
theft)
6. Property accounting
7. Pollution and noise control
8.
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Objectives of Plant Maintenance:



► To maximize the amount of time the assets

will be available for use.
► To preserve the value of assets by reducing
the rate at which they deteriorate.
► To perform the maintenance activities in a
most economical manner.
► To plan and schedule maintenance work so as
to anticipate and prevent interruptions in
operations.
► To perform the activities of inspection,
adjustments, repairs, replacements, and
operation of the shops.
► To improve the quality of products and to
improve productivity.
► To minimize the total maintenance cost.
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Functions of Maintenance Management:



1. Inspection
2. Repair
3. Overhaul
4. Lubrication
5. Salvage
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Types of Plant Maintenance:



1. Breakdown Maintenance:
 repairs are made after the equipment is out of
order and it cannot perform its normal
functions any longer.
 Equipments/machines must be repaired on an
urgent basis.


2. Preventive Maintenance:
 Maintenance activities undertaken before the
machines or equipments fail.
 To minimize possibility of major break-downs.


5. Predictive Maintenance:
 Sensitive instruments (vibration analysers,
amplitude meters) are used to predict trouble.
3.
5. Routine Maintenance:
 Running Maintenance: maintenance work is
carried out while the equipment is in the
operating condition. (eg. Greasing or
lubricating)
 Shut down Maintenance: maintenance work is
carried out when the machine is out of service.
(Eg. Reparing boiler tubes of boiler)


6. Planned Maintenance:
 Maintenance activities that are carried out
according to a predetermined schedule.
 It involves inspection fo all plant and
equipments, machinery, buildings in order to
service.
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Causes of breakdown:


► Failure to identify and replace worn-out

parts
► Lack of lubrication
► Inefficient or neglected cooling system
► Indifference towards minor faults
► too low or too high voltage
► Use of sub-standard or wrong fuel
► Indifference towards vibration/sound in the
system