Post on 01-Nov-2014
description
MAINTENANCE MANAGEMENT
BY
SHEREEN SHAHANA & MARY JASMINE D
WHAT IS MAINTENANCE? MAINTENANCE IS THE PROCESS OF
KEEPING MACHINE AND EQUIPMENT IN GOOD WORKING CONDITION SO THAT THE EFFICIENCY IS RETAINED AND ITS LIFE IS INCREASED.
IT’S A COMBINATION OF ACTIONS CARRIED OUT BY AN ORGANIZATION TO REPLACE,REPAIR,SERVICE THE MACHINES,COMPONENTS OR THEIR GROUPS IN A MANUFACTURING PLANT,SO THAT IT WILL CONTINUE TO OPERATE SATISFACTORILY.
FUNCTIONS OF MAINTENANCEa) INSPECTIONb) REPAIRc) OVERHAULd) LUBRICATIONe) SALVAGE
INSPECTION PERIODIC CHECKING OF MACHINES GIVING PROPER ATTENTION TO THOSE
EQUIPMENTS REQUIRED WORK IN INTERVALS
DETERMINATION OF REPAIR FEASIBILITY CONTROL OF QUALITY WORK DETECTION OF FAULTS BEFORE
BREAKDOWN OF EQUIPMENT
REPAIR PROCESS OF REPARING THE
COMPONENT OR REPLACING THE ITEM OR PART BY ANOTHER ITEM TO RESTORE FAILED OR BROKEN DOWN ITEM IN WORKING ORDER.
OVERHAUL FALLS UNDER PREVENTVE MAINTENANCE . FREQUENCY OF OVERHAULING IS LESS THAN
LUBRICATION AND INSPECTION. HERE THE MACHINE IS STRIPPEDAND THE
VARIOUS PARTS ARE CLEANED AND OILED AND COMPONENTS ARE REPLACED.
LUBRICATION HELPS IN MAINTAINING THE MACHINE
ACCURACY AND INCREASE LIFE OF MACHINE.
IT IS DONE BY THE OPERATOR ITSELF. LUBRICATION CAN BE
DAILY,WEEKLY,FORTNIGHTLY,MONTHLY.
MAINTENANCE PRACTICES DIFFERENT MAINTENANCE PRATICES
ARE ADOPTED TO SUIT THE VARIOUS TYPES OF PRODUCTION MACHINERIES AND OTHER DEVICES.THEY ARE:-
I. BREAKDOWN MAINTENANCEII. PREVENTIVE MAINTENANCEIII. SCHEDULED MAINTENANCEIV. PRODUCTIVE MAINTENANCE
1.BREAK DOWN MAINTENANCE MACHINES ARE ALLOWED TO RUN
WITHOUT CARRYING OUT ANY MAINTENANCE.
ONLY WHEN IT BECOMES OUT OF ORDER(STOP WORKING) IT IS REPAIRED
NEXT MAINTENANCE IS DONE ONLY WHEN IT BREAKS DOWN.
APPLICABLE TO MACHINES WHICH ARE NOT IMPORTANT i.e; BREAK DOWN OF THESE MACHINES WILL NOT AFFECT THE PRODUCTION PROCESS
CAUSES OF BREAKDOWN:
I. FAILURE TO REPLACE THE WORNOUT PARTS
II. NON APPLICATION OF LUBRICANTSIII. NEGLECTED COOLING SYSTEMIV. CARELESSNESS TOWARDS MINOR
REPAIRS.
2.PREVENTIVE MAINTENANCE AIMED AT AVOIDING OR PREVENTING
BREAKDOWNS. THE PRINCIPLE OF PREVENTIVE
MAINTENANCE IS ‘PREVENTION IS BETTER THAN CURE’
HERE SOME COMPONENTS ARE IDENTIFIED AS WEAK SPOTS IN ALL MACHINERIES AND EQUIPMENTS.
THESE PARTS ARE INSPECTED REGULARLY. MINORS REPAIRS ARE CARRIED OUT
IMMEDIATELY AS SOON AS THERE IS NECESSITY AVOIDING UNANTICIPATED BREAKDOWNS.
3.SCHEDULED MAINTENANCE MAINTENANCE DONE ACCORDING TO
RECOMMENDATIONOF THE SUPPLIER OF THE EQUIPMENT.
DONE AT PREDETERMINED DATES. Eg. OVERHAULING OF
MACHINES,CLEANING OF TANKS,ANNUAL SHUT DOWN AND MAINTENANCE OF POWER PLANTS etc..
IN THIS PLANT IS SHUTDOWN NAD FOLLOWING ARE DONE:
o INSPECTION,REPAIRING AND REPLACING OF WORN OUT PARTS.
PRODCUTIVE MAINTENANCE TYPE OF PREVENTIVE MAINTENANCE. IT IS DONE ONLY FOR CRITICAL MACHINERIES. Eg. IN A CHEMICAL PLANT A SMALL PUMP FOR
CIRCULATING CHEMICALS MAY BE A CRITICAL EQUIPMENT IF THE PUMP FAILS TO FUNCTION THEN THE WHOLE PLANT HAVE TO BE STOPPED.SO THE PUMP IS CONSIDERED TO BE A CRITICAL EQUIPMENT IN THE CHEMICAL PLANT.THIS PUMP WHICH IS IDENTIFIED AS A CRITICAL EQUIPMENT SHOULD BE GIVEN PREVENTIVE MAINTENANCE.
ADVANTAGES OF MAINTENANCE
LIFE OF MACHINERY AND EQUIPMENS ARE INCREASED.
PRODUCTION TAKES PLACE AS PER THE SCHEDULE.
PRODUCTS ARE DELIVERED TO CUSTOMERS IN TIME AND HENCE HIGH LEVEL OF CUSTOMER SATISFACTION CAN BE EXPECTED.
MACHINES ARE IN GOOD CONDITION.HENCE QUALITY OF THE PRODUCTS WILL BE GOOD.
NO PRODUCTION LOSS. MACHINERY IS NOT DAMAGED. NO IDLE TIME OF MEN AND MACHINES.HENCE
THEIR UTILITY INCREASES.
DISADVANTAGES OF POOR MAINTENANCE MACHINERY MAY BE DAMAGED.THIS IS A
LOSS. POORLY MAINTAINED MACHINES WILL
PRODUCE POOR QUALITY PRODUCTS. MORE WASTAGE OF MATERIALS. BREAK DOWN OF MACHINES MAKES
BOTH MEN AND MACHINE IN IDLE POSTION.SO PRODUCTION TIME IS WASTED.THIS WILL INCREASE COST OF PRODUCTION.
POOR MAINTENACE CAUSE ACCIDENTS. DUE TO POOR MAINTENACE LIFE OF
MACHINE IS REDUCED.
Thank you..