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LESSON 1
1. Introduction to Maintenance Management
Why do we study maintenance?
The management of maintenance is gaining importance as one of the key factors in increasing
the productivity of a company. The maintenance has so discernible influence on the quality of
production processes that production industries can no longer function without maintenance.
And the quality of the production process has a direct influence on the quality of the products
and the costs of production. Besides, it is also to be noted that maintenance influences the
availability of the equipment, which influences the production's conformity to the production
schedule. Therefore reasons for studying maintenance can be divided into the following groups:
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quality of products - Companies are incurring heavy loses resulting from sub-standard
products due to defective machinery. These products have to be recycled or thrown out as
scraps. To avoid such kind of costs, maintenance of equipment needs to be emphasised.
reliability of production system - reliability of production system depends on the availability
of the installed machinery and equipment.
economical aspects - the cost of not doing proper maintenance is too huge. Therefore to
avoid such costs, managers should understand the importance of carrying out proper
maintenance.
organisational aspects - proper co-ordination of maintenance and production workorders
so as to avoid conflicts in these two departments.
safety matters - Most of the industrial accidents occur due to defective equipment. When
an accident takes place there is a danger of polluting the environment, operator injury or
even destruction of the equipment.
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Maintenance
management
Maintenance
work planning
Maintenance
programming
Maintenance
controlling
Maintenance
analysis
Maintenance
strategy planning
Maintenance
programm
Releasing of
workorders
Analysis of
deviations
Personnel
planning
Maintenance
schedule and
capacity
Monitoring of
workorders
Analysis of
weak points
Material
planning
Maintenance
procurements
Budgeting
Consultation
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Operational availability is defined here as the probability that a piece of equipment, when used
in actual operational environment under specified conditions will operate (i.e. do its job)
satisfactorily when called upon. It is usually indicated by the proportion of official time during
which the equipment is in operational or able to operate condition. By official time it is meant the
time during which the equipment is expected to be in running condition (for production or other
business functions).
1.2.2 Breakdown maintenance (This means planned Corrective Breakdown maintenance.)
Breakdown maintenance is a work that is carried out after a failure, but for which advance
provision has been made in the form of spares, materials, labour and equipment. (cf. definitions
for Repair Maintenance, Corrective Maintenance, Unscheduled Maintenance, Unplanned
maintenance, and Emergency Maintenance).
1.2.3 Check
Check in this context is defined as to compare with an acceptable standard by suitable or
defined means, whilst the facility is non-operational.
1.2.4 Clean
The term Clean in maintenance is defined as to reduce contamination to an acceptable standard
1.2.5 Condition Based Maintenance (Predictive Maintenance)
This is a special type of preventive maintenance in which a continuous monitoring of the
condition of the equipment is done and maintenance is done only when necessary. This also
can be performed in either a running or shutdown condition.
1.2.6 Corrective maintenance (This means planned corrective maintenance.)
Corrective maintenance can be defined as work undertaken to restore a facility to an acceptable standard.
1.2.7 Downtime
Period during which a facility is not ready for use
1.2.8 Emergency maintenance (This means unplanned emergency maintenance.)
Emergency maintenance is the work necessitated by unforeseen breakdowns or damage.
1.2.9 Facility register
A record of facilities including information such as constructional and technical details about
each piece of equipment. This may be combined with an inventory
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1.2.10 Failure
Mechanical failure refers to inability of a component or part of a piece of equipment to perform it
designed function. Failure occurs at a point where stress toward which a part is subjected to
exceeds the strength of the part at that time.
1.2.11 Failure Rate
Failure rate is defined as the number of failures per period of time during which failure can
occur. Failure rate is normally presented in terms of failures per hour or other multiples of hour.
Failure rate can also be presented in terms of the number of operations or number of cycles.
1.2.12 Fault report
Fault report is a document reporting deviation of a facility from an acceptable standard.
1.2.13 History card
History card is a document on which information about all work done on and/or by a particular
facility is recorded.
1.2.14 Inspection
Inspection in this context will be defined by DIN 31051 as "actions for substantiating and assessing the real-condition of the technical system". Inspection activities verify the level of wear
and tear of a technical system. According to BS Inspection is the process of ensuring by assessment that a facility reaches the necessary standard of quality or performance and that the
level is maintained.
1.2.15 Inventory
Inventory is a list of all facilities, i.e. all parts of a site, building and contents, for purposes of
identification.
1.2.16 Job interval
Job interval is the period, which may be based on time or other factors, between occurrences of
a particular maintenance job
1.2.17 Job report
Job report is a statement recording the work done and the condition of the facility
1.2.18 Job card
Job card is a document requesting the maintenance work to be done
1.2.19 Job specification
Job specification is a document describing the maintenance work to be done
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1.2.20 Maintainability
Maintainability can be defined as the inherent characteristic of a design or installation that
determines the ease, economy, safety, and accuracy with which maintenance actions can be
performed.
1.2.21 Maintenance management
Maintenance management is the organization of maintenance within an agreed policy
1.2.22 Maintenance Prevention (Design-out Maintenance, Renovate Maintenance,
Improvement Maintenance)
Design or redesign of the equipment or part of the equipment for minimal or, ideally, no maintenance. The re-design of the equipment or part of the equipment can take place either while the
equipment is running or is shutdown
1.2.23 Maintenance schedule
Maintenance schedule is a comprehensive list of maintenance tasks and their incidence
1.2.24 Maintenance strategy
Maintenance strategy planning can be defined as a principal function of planning, whereby the
type of maintenance, the extent of doing and the time of carrying out of maintenance actions
will be established. The maintenance strategy for each piece of equipment can therefore be
defined as the determination of the maintenance actions for this piece of equipment, the establishment of the time of accomplishing the maintenance actions and the fixing of the type of
maintenance personnel to carry out the maintenance actions.
1.2.25 Overhaul
Overhaul can be defined as a comprehensive examination and restoration of a facility, or a
major part thereof to an acceptable standard (Other terms used include: RECONDITION,
REFIT, and REBUILD)
1.2.26 Permit to work
Permit to work is a signed document, authorizing access to a facility, which must define conditions, including safety precautions, under which work may be carried out. This may include a
document, signed on completion of maintenance, stating that a facility is safe and ready for
use.
1.2.27 Planned maintenance
Planned maintenance is work organized and carried out with forethought, control and records
1.2.28 Preventive maintenance (This means planned preventive maintenance)
Preventive maintenance is a work, which is directed to the prevention of failure of a facility
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Maintenance
Planned Maintenance
Preventive
Maintenance
Regular Preventive
Maintenance
Unplanned
Maintenance
Corrective
Maintenance
Condition based
Maintenance
Breakdown
Maintenance
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