OPERATIONS MANAGEMENT
MAINTENANCE
It refers to that function of production management concerned with day to day problem of keeping physical plant in good operating condition.
MAINTENANCE MANAGEMENT
- Maintenance Management involves maintenance planning, maintenance scheduling, execution of maintenance activities (repair, breakdown and preventive maintenance) and also controlling costs of maintenance.
- Maintenance Management is concerned with direction and organization of resources in order to control availability and performance of industrial plant to some specified level.
OBJECTIVES OF MAINTENANCE MANAGEMENT
- Minimizing loss of productive time because of failure.
- Minimizing repair time and repair cost.
- Minimizing any loss due to production stoppages.
- Minimize accidents by regular inspection.
- Minimize total maintenance cost which include cost of repair, inventory carrying cost ,spare parts inventory.
- Maximize life of capital asset.
- Maximize efficiency and economy in production through use of facilities.
- Efficient use of maintenance personnel & equipment.
- To keep all productive assets in good working.
- To maximize efficiency & economy.
- To improve the quality of products & to improve productivity.
IMPORTANCE
Plant and equipment are heart of a production system. Therefore, proper maintenance of plant and equipment is essential for keeping them in good working condition. This ensures optimum utilization of production facilities and resources. All production equipment is designed to give a predetermined quantity and quality of output. This objective can be realized only when the equipment is supported by proper maintenance. In the absence of timely upkeep, even the best machine will ultimately breakdown untimely. Regular used over a period of time causes wear and tear. Gear become loose, bolts tear off, valves get choked, parts crack, pipes leak, lubricant dries etc. Therefore, regular inspection, lubrication, repair etc., must be undertaken to maintain the reliability and efficiency of equipment. Proper maintenance helps to maximize production performance by preventing breakdowns and by minimizing the loss caused by breakdown.
- It helps in identify the cause of failure , e.g. whether the failure is due to design defect, or a wear out failure.
- It also helps in deciding the type of maintenance and maintenance decision like replace and repair.
- It provides the necessary information regarding the life and reliability of the equipment.
- With the help of this tool spare parts management got initiated.
TYPES OF MAINTENANCE
- Breakdown Maintenance
- Preventive Maintenance
- Predictive Maintenance
BREAKDOWN MAINTENANCE:
- In this type, actions such as repair, replacement, or restore will be carried out after the occurrence of a failure in order to eliminate the source of this failure or reduce the frequency of its occurrence.
- It also include the different types of actions like typical adjustment of redesign equipment.
- The difference between Breakdown maintenance and Preventive maintenance is that for the Breakdown maintenance, the failure should occur before any corrective action is taken.
It means that people waits until equipment fails and repair it. Such a thing could be used when the equipment failure does not significantly affect the operation or production or generate any significant loss other than repair cost.
Advantages
- Maintenance cost low.
- Replacement cost low.
- Saves inspection time.
Disadvantages
- Results in dislocation of production process.
- Causes delay or reduction in output.
- Results in loss of profit because wages are paid for idle time.
- Failure of machine may cause accidents leading to losses and troubles.
PREVENTIVE MAINTENANCE:
- It is based upon the principle that ‘prevention is better than cure’.
- It is a set of activities that are performed on plant equipment, machinery, and systems before the occurrence of a failure in order to protect them and to prevent or eliminate any degradation in their operating conditions.
- The maintenance carried out at predetermined intervals or according to prescribed criteria and intended to reduce the probability of failure or the degradation of the functioning and the effects limited.
- It has three types
- Running maintenance
- Scheduled maintenance
- Shutdown maintenance
- Running maintenance: Running maintenance which includes those maintenance activities that are carried out while the machine or equipment is running. Example – lubrication, adjustment of nuts and screws, tightening of loose nut and bolts.
- Scheduled Maintenance: Scheduled Maintenance is any variety of scheduled maintenance to an object or item of equipment. Specifically, Planned Maintenance is a scheduled service visit carried out by a competent and suitable agent, to ensure that an item of equipment is operating correctly and to therefore avoid any unscheduled breakdown and downtime. Good example of PM program is car maintenance. After so many kilometers or miles oil should be changed, parts renewed.
- Shutdown Maintenance: Which is a set of preventive maintenance activities that are carried out when the production line is in total stoppage situation. These are performed generally after three or six months. These involves the inspection of plant items which are known or suspected to occur.
Advantages
- It result in consequent reduction in production losses.
- Reduction in number of major repair.
- Reduction in no. of accidents.
- Reduction in inventory of spare parts.
- Improvement in product quality.
Disadvantages
- Wages of preventive maintenance technicians and staff.
- Minor cost such as record keeping.
- Instruments used to monitor conditions.
PREDICTIVE MAINTENANCE:
- As the names implies it involves the prediction of the failure before it occurs, identifying the root cause for those failures symptoms and eliminating those causes before they result in extensive damage of the equipment.
- Type of maintenance performed continuously or at intervals according to the requirements to diagnose and monitor a condition or system. Also called condition based maintenance.
Advantages
- Increased operational life.
- Better quality products.
- Energy saving.
- Improved worker safety.
- Allow prior corrective actions.
Disadvantages
- Increased investment in diagnosis and staff training.
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