ENGG ZC242

Maintenance & Safety

BITS Pilani
Pilani Campus

Girish Kant
Department of Mechanical Engineering
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BITS Pilani
Pilani Campus

Introduction to Maintenance
Systems
Chapter 1, Lecture-1

Learning Objectives
Course Handout

Definitions of Maintenance
History of Maintenance
Maintenance Objectives/Scope and Benefits/Policies

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Course Description
Objectives, Functions, and Types of maintenance
Defect due to wear, lubrication, maintenance of different
equipments and their elements
Management of maintenance function, spares planning,
overhauling and TPM
Safety and safety management, environmental safety,
chemical safety, occupational health management,
control of major industrial hazards, managing
emergencies, employee participation in safety and HRD
for maintenance and safety.

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Scope and Objectives

The objective of the course is to make students
understand the concepts of maintenance and safety
and their importance in industry.
The course deals with the planning and control of
various maintenance engineering.
The learning of the basic and recent trends in
maintenance engineering will help the students in their
professional life. The safety portion the course will
enable the students to deal with effectively the various
types of hazard in industry.

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Prescribed Text Book

K.

Venkataraman,

Maintenance

Engineering

and

Management, Prentice Hall of India, 2007.

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Reference Books
Mishra R.C. & K. Pathak, Maintenance Engineering and
Management, Prentice-Hall of India., 2002
Sushil Kumar Srivastava, Industrial Maintenance
Management, S. Chand & Company, 2002.
Krishnan N.V., Safety Management in Industry, Jaico
Publishing House, 1993.
L M Deshmukh, Industrial Safety Management, TMH,
2006.

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Reference 247 e-Books

www.books24x7.com
Maintenance

Management:

Its

Auditing

and

Benchmarking: In Search of Maintenance Management

Excellence by Anthony Kelly , Industrial Press 2006
(336 pages) Citation

Total Productive Maintenance

by Terry Wireman ,

Industrial Press 2004 (204 pages)

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Plan of Study - I
Week No. Chapter Name

Objective/Topic

Introduction to Maintenance Systems

Maintainability

Maintenance as Business Proposition,

T1-Chapter 1
Maintenance Philosophy, Types of
Maintenance systems
Measure of maintainability, Methods of T1-Chapter 2
Evaluation of Maintainability, Design for
Maintainability

3-4

Condition-Based Maintenance (CBM)

5-6

Reliability Centred Maintenance (RCM) Reliability being active and standby,

FMECA, RCFA, Criticality analysis
Asset management function, EOQ, 2-Bin
Asset and Spare Parts Management
system of material procurement,
computing
Maintenance Lubricants and Their
Applications
Key Definitions in Lubrication

Improvement effectiveness thru CBM,

various CBM techniques

Reference to
Text Books

T1-Chapter 3

T1-Chapter 4
T1-Chapter 5

Appendix I
Appendix II

Review Session
Syllabus for Mid- Semester Test (Closed Book): Topics in Week No. 1 to 9
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Plan of Study - II
Week No.

Chapter Name

Objective/Topic

10-11

Safety Engineering and Fault Tree Analysis

Hazard analysis, , General rules in fire T1-Chapter 6

hazard and safety, Faulty tree analysis

12

Total Productive Maintenance

13

Maintenance Planning and Scheduling

Methodology, Origin, Implementation, T1-Chapter 7

Lean Maintenance, Training and
monitoring
Maintenance planning, Shutdown
T1-Chapter 8
planning and execution

14

Computer Applications in Maintenance

Management

CMMS, data acquisition, software

failure, software security

T1-Chapter 9

15

Statistical Distribution in Preventive

Maintenance

T1-Chapter 10

16

Maintenance Integration

Types of distributions, Normal

distribution, Gamma distribution,
Binomial distribution etc.
Steps of integration, future trends

17

Maintenance Effectiveness

18

Review Session

Reference to Text
Books

T1-Chapter 11

Elements of effectiveness,
T1-Chapter 12
Presentation of data, OEE, Agility etc.

Syllabus for Comprehensive Exam (Open Book): All topics given in plan of study (I & II)
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Evaluation Scheme
EC
No.

Evaluation
Duration
Component &
Type of Examination
EC-1 Quiz
--

Weightage

Day, Date,
Session,Time

15%

-Sunday,
14/09/2014 (AN)
2 PM 4 PM
Sunday,
09/11/2014 (AN)
2 PM 5 PM

EC-2 Mid-Semester Test

(Closed Book)*

2 Hours

35%

EC-3 Comprehensive
Exam
(Open Book)*

3 Hours

50%

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Evaluation Scheme (EC-1 Quiz)

EC-1 No.

Syllabus

Weightage

To be
administered
online during

Quiz 1

Chapter 1-3

5%

Quiz 2

Chapter 4-6,
Appendix I & II

5%

August 16 to
January 26, 2014
September 16 to
September 26,
2014

Quiz 3

Chapter 7-12

5%

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October 13 to
October 23, 2014

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Nature of Exam
Closed Book Test: No reference material of any kind will
be permitted inside the exam hall.
Open Book Exam: Use of any printed / written reference
material (books and notebooks) will be permitted inside
the exam hall. Loose sheets of paper will not be
permitted. Computers of any kind will not be allowed
inside the exam hall. Use of calculators will be allowed in
all exams. No exchange of any material will be allowed.

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Note
It shall be the responsibility of the individual student to be regular in
maintaining the self study schedule as given in the course handout, attend
the online/on demand lectures as per details that would be put up in the
BITS LMS Taxila website www.taxila.bits-pilani.ac.in and take all the
prescribed components of the evaluation such as Assignment (Course Page
on LMS Taxila), Mid Semester Test and Comprehensive Examination
according to the Evaluation Scheme given in the respective Course Handout.
If the student is unable to appear for the Regular Test/Examination due to
genuine exigencies, the student must refer to the procedure for applying for
Make-up Test/Examination, which will be available through the Important
Information link on the BITS WILP website on the date of the Regular
Test/Examination. The Make-up Tests/Exams will be conducted only at
selected exam centres on the dates to be announced later.

BITS Pilani, Pilani Campus

BITS Pilani
Pilani Campus

Introduction to Maintenance
Systems
Chapter - 1

What is Maintenance?
Maintenance refers to all the activities which assist in

keeping plant & equipment in good condition.

Any

activity

such

as

tests,

measurements,

replacements, adjustments and repair, intended to

restore or retain a functional unit in a specified state in
which the unit can perform its required functions.

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Maintenance Definitions
Maintenance is not merely preventive maintenance,
although this aspect is an important ingredient.
Maintenance is not lubrication, although lubrication is
one of its primary functions.
Maintenance simply a frenetic rush to repair a broken
machine part or building segment, although this is more
often than not the dominant maintenance activity.

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Maintenance Definitions
Maintenance is a science since its execution relies,
sooner or later, on most or all of the sciences.
It is an art because seemingly identical problems
regularly demand and receive varying approaches and
actions and because some managers, foremen, and
mechanics display greater aptitude for it than others
show or even attain.
It is above all a philosophy because it is a discipline
that can be applied depending upon a wide range of
variables that frequently transcend more immediate and
obvious solutions. ENGG ZC242, Maintenance and Safety,
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Maintenance Definitions
Maintenance is a philosophy because it must be
carefully fitted to the operation or organization. it serves
as a fine suit of clothes is fitted to its wearer because
the way it is viewed by its executors will shape its
effectiveness.

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Maintenance Definition
Maintenance can be defined as a set of activities that
ensure any physical asset to continue to fulfill its
intended functions to the standard of performance
desired by the user.

Repair & Maintenance

Is fixing or setting things all right for any sort of
mechanical or electrical devices if the same gets out of
the order or broken down as well as performing the
routine actions which keep the device in working order or
prevent trouble from arising.
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History of Maintenance
Pre world war II (pre 1945)
1945-1970
1970 onwards

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Maintenance Objectives
Operational

Maximum operating efficiency of plant

Maximum availability of plant
High Quality performance
Safety
To maintain a plant clean & good appearance
To extend Plant life to the last limit
To reduce environmental impact due to machinery etc
To provide service that will avert all breakdowns at all times at any cost.

Cost
Minimize maintenance expenditure and maximize profits
To provide activities with in the limits of budgetary control

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Maintenance Benefits
Financial

Organizational
Technical
Human
Customer relations

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Financial Benefits
Extended Plant Life

Uninterrupted production
Improved quality of production
Reduced production delays
Reduced cost of repairs

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Organizational Benefits
Co-ordination between production and maintenance

Man power planning

Planning of deliveries

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Technical Benefits
Improved equipment suitability

Build up of technical data

Improved maintenance schedules
Improved plant condition

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Human considerations
Benefits
Increased Safety

Improved House keeping

Less friction between relationships

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Customer relationship
Benefits
Reliable delivery calls

Show case house keeping

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Maintenance Policy
Scope and limits of maintenance

Type and level of service expected

Responsibilities to management
Personal Practices
Trade union contracts
Budget and financial controls

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Maintenance Functions
Primary Functions

Maintenance of existing plant equipment

Maintenance of existing plant buildings and grounds
Equipment inspection and lubrication
Utilities generation and distribution
Alterations and new installations

Secondary Functions

Storekeeping
Plant protection
Waste disposal
Salvage
Insurance
Other services

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What does maintenance really

do?
Repair, lubrication, overhaul, inspection, replacement of
parts
Training of the maintenance staff
Training of the production staff
Testing parts for suitability
Planning of servicing schedules
Improvement and modifications of plant
Production of spare parts

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Maintenance System of Today

Protecting the buildings, structures and plants.
Increase equipment availability & reducing
downtime.
Controlling & directing labour forces.
Economy in maintenance department.
Maximum utilization of available resources.
Preparing maintenance budgets.
Emphasis on waste recovery.
Improving technical communication.
Preventing waste of tools, spare and other materials.
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For achieving these objectives various

control functions & actions are to be taken
which would be discussed in subsequent
chapters.

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Summary
Comment on the following statements
Maintenance is a necessary evil
Maintenance is a bottomless pit for expenses
Maintenance is known as Time lag effect

Maintenance is a composite function

Lesser the demand better the service
What type of conditions prevailing with in the company that
affect the demand upon the maintenance department?
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Thanks

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