MAINTENANCE ENGINEERING ANDMANAGEMENT

Second Edition

R.C. MishraK. Pathak

MAINTENANCE ENGINEERINGAND MANAGEMENT

SECOND EDITION

R.C. MISHRAFormer Director

Aryavart Institute of Technology and ManagementLucknow

K. PATHAKProfessor

Department of Mining EngineeringIndian Institute of Technology Kharagpur

Kharagpur

New Delhi-1100012012

MAINTENANCE ENGINEERING AND MANAGEMENT, Second EditionR.C. Mishra and K. Pathak

© 2012 by PHI Learning Private Limited, New Delhi. All rights reserved. No partof this book may be reproduced in any form, by mimeograph or any othermeans, without permission in writing from the publisher.

ISBN-978-81-203-4573-7

The export rights of this book are vested solely with the publisher.

Ninth Printing (Second Edition) . . . . . . April 2012

Published by Asoke K. Ghosh, PHI Learning Private Limited, M-97, ConnaughtCircus, New Delhi-110001 and Printed by Meenakshi Art Printers, Delhi-110006.

iii

Preface ix

Preface to the First Edition xi

1. MAINTENANCE CONCEPT 1–27

Introduction ........................................................................................... 1Maintenance Definition ....................................................................... 3Systems Approach ................................................................................ 4Challenges in Maintenance ................................................................ 6Maintenance Objectives ....................................................................... 7Maintenance Levels ............................................................................. 9Responsibilities of Maintenance Department .................................. 10Types of Maintenance Systems .......................................................... 12Benefits of Maintenance ...................................................................... 19Effects of Maintenance ........................................................................ 20Concept of Maintainability ................................................................. 21Principles of Maintenance ................................................................... 22Research and Development in Maintenance .................................... 24Role of Overhauling in Maintenance ................................................ 26Expert System in Maintenance .......................................................... 26

Questions ............................................................................................... 27

2. PLANNED PREVENTIVE MAINTENANCE 28–49

Introduction ........................................................................................... 28Scope of Preventive Maintenance ...................................................... 30Elements of PPM ................................................................................. 31Implementation of PPM ...................................................................... 36Administrative Structure .................................................................... 36Work Planning and Scheduling ......................................................... 37Workload Estimation ........................................................................... 38Manpower Estimation .......................................................................... 38Scheduling PPM ................................................................................... 38Work-order Procedure .......................................................................... 39Creating a Set of Priority Functions ................................................ 39Forecasting Maintenance Requirements ........................................... 40Planned Maintenance Procedure ........................................................ 40Effectiveness of Preventive Maintenance ......................................... 41Benefits of PPM ................................................................................... 43Maintenance by Objectives ................................................................. 45Development of Checklists .................................................................. 47Improving Skills of Maintenance Personnel .................................... 48

Questions ............................................................................................... 49

Contents

3. MAINTENANCE EVALUATION 50–60

Introduction ........................................................................................... 50Background of Maintenance Function ............................................... 51Need of Evaluation .............................................................................. 52Maintenance Function Requirements ................................................ 52Benefits of Maintenance Evaluation ................................................. 53Types of Evaluation ............................................................................. 54Statistical Analysis of Performance .................................................. 58Selection of Work Measurement Methods ........................................ 59Cost of Maintenance Evaluation ........................................................ 59

Questions ............................................................................................... 60

4. CONDITION MONITORING 61–83

Introduction ........................................................................................... 61Basic Concept ....................................................................................... 62Levels of Condition Monitoring .......................................................... 64Condition-Monitoring Techniques ...................................................... 65Future of Condition Monitoring ......................................................... 78Case Study ............................................................................................ 82

Questions ............................................................................................... 82

5. MAINTENANCE PLANNING AND SCHEDULING 84–102

Introduction ........................................................................................... 84Planning of Maintenance Function ................................................... 85Manpower Allocation ........................................................................... 87Long-range Planning ............................................................................ 90Development of Maintenance Department ....................................... 91Short-range Planning ........................................................................... 92Planning Techniques ............................................................................ 93Planning Procedure .............................................................................. 95Estimation of Maintenance Work ...................................................... 96Maintenance Control ........................................................................... 97Maintenance Scheduling ..................................................................... 98

Questions ............................................................................................... 101

6. MOTIVATION IN MAINTENANCE 103–115

Introduction ......................................................................................... 103Characteristics of Motivation ........................................................... 104Implications of Motivation Theories ................................................ 105Special Issues in Motivation ............................................................ 107Maintenance Training ....................................................................... 107Training Problems .............................................................................. 108Training Programmes ........................................................................ 109Training Facilities .............................................................................. 110Incentives in Maintenance ................................................................ 110Labour Performance Analysis .......................................................... 111Measuring Performance Improvement ............................................ 112

Questions ............................................................................................. 114

iv Contents

7. COMPUTERS IN MAINTENANCE 116–130

Introduction ......................................................................................... 116Computer-Aided Maintenance .......................................................... 117Computerized Maintenance Models ................................................. 125Maintenance Decision Making ......................................................... 126Computerized Maintenance Planning ............................................. 128

Questions ............................................................................................. 130

8. RELIABILITY IN MAINTENANCE 131–152

Introduction ......................................................................................... 131Reliability .......................................................................................... 132Failure Functions and Their Models ............................................... 137Reliability Application ....................................................................... 140Design for Reliability ......................................................................... 146Quality and Reliability ...................................................................... 148Reliability Improvement .................................................................... 149Reliability Testing .............................................................................. 149

Questions ............................................................................................. 152

9. DEVELOPMENT OF MAINTENANCE ENGINEERINGPRACTICES 153–164

Introduction ......................................................................................... 153Tribology Practices ............................................................................. 153Terrotechnology Practices ................................................................. 156Indigenous Substitution .................................................................... 157Reconditioning .................................................................................... 157Advanced Strategies ........................................................................... 158Instrumented Equipment Monitoring .............................................. 163

Questions ............................................................................................. 163

10. ECONOMIC ASPECTS OF MAINTENANCE 165–178

Introduction ......................................................................................... 165Life Cycle Costing .............................................................................. 165Maintenance Cost ............................................................................... 167Impact of Maintenance Cost ............................................................. 168Maintenance Budget .......................................................................... 169Cost Control ........................................................................................ 171Absenteeism and Overtime ............................................................... 172Maintenance Audit ............................................................................. 173

Questions ............................................................................................. 177

11. ORGANIZATIONAL STRUCTURE FOR MAINTENANCE 179–191

Objectives of Maintenance Organization ........................................ 179Maintenance Functions and Activities ............................................ 181Organizational Requirements ........................................................... 181Organizational Problems ................................................................... 184Types of Maintenance Organizations .............................................. 185

Contents v

Cost Minimization in Maintenance Organizations ........................ 189Updating Maintenance Organizations ............................................. 190

Questions ............................................................................................. 191

12. MAINTENANCE EQUIPMENT AND FACILITIES 192–202

Introduction ......................................................................................... 192Workshops ........................................................................................... 194Stores ................................................................................................... 200

Questions ............................................................................................. 202

13. MAINTAINABILITY 203–211

Introduction ......................................................................................... 203Maintainability and Its Cost ............................................................ 205Maintainability Analysis ................................................................... 207Functional Analysis ........................................................................... 207Maintainability Prediction ................................................................ 208Design for Maintainability ................................................................ 209Cost Effectiveness .............................................................................. 210

Questions ............................................................................................. 211

14. LUBRICANTS AND MAINTENANCE 212–221

Introduction ......................................................................................... 212Lubrication Systems .......................................................................... 213Role of Lubricants .............................................................................. 219Hi-tech Oils and Lubricants ............................................................. 219Impact of Environment on Lubricants ............................................ 220

Questions ............................................................................................. 221

15. MAINTENANCE MATERIAL PLANNING ANDCONTROL 222–231

Introduction ......................................................................................... 222Present Material Management Policies .......................................... 223Information System ........................................................................... 224Classification of Spares ..................................................................... 224Inventory Costs .................................................................................. 225Spare Parts Cost Optimization ........................................................ 225Spare Parts Provisioning .................................................................. 226Stores Management ........................................................................... 228Spare Parts Inventory ....................................................................... 229Spares Control .................................................................................... 230

Questions ............................................................................................. 231

16. DECISION MAKING IN MAINTENANCE 232–243

Introduction ......................................................................................... 232Problems in Making Rational Decisions ......................................... 234Information for Decision Making ..................................................... 237

vi Contents

Decision Models .................................................................................. 237Limitations of Failure Statistics ...................................................... 238Information Collection ....................................................................... 238Use of Pooled Information ................................................................ 240R&D in Maintenance ......................................................................... 240Behavioural Concepts in Decision Making ..................................... 242

Questions ............................................................................................. 242

17. ENVIRONMENTAL IMPACT ON MAINTENANCE 244–250

Introduction ......................................................................................... 244Design Improvements ........................................................................ 248Pollution Prevention .......................................................................... 249

Questions ............................................................................................. 250

18. MANPOWER PLANNING FOR MAINTENANCE 251–262

Introduction ......................................................................................... 251Objectives of Manpower Planning ................................................... 253Stages of Manpower Planning .......................................................... 253Timescale of Manpower Planning .................................................... 255Manpower for Maintenance Systems .............................................. 258Manpower Estimation Mode ............................................................. 260

Questions ............................................................................................. 261

19. ENERGY CONSERVATION AND MAINTENANCE 263–267

Introduction ......................................................................................... 263Some Design Factors for Energy Conservation ............................. 263Role of Safety Engineering in Maintenance .................................. 266

Questions ............................................................................................. 267

20. MAINTENANCE OF MECHANICAL ANDELECTRICAL SYSTEMS 268–280

Introduction ......................................................................................... 268Bearings .............................................................................................. 268Friction Clutches .................................................................................... 270Couplings .............................................................................................. 270Fastening Devices .................................................................................. 271Chains .................................................................................................. 271Gear Drives ......................................................................................... 272Support Equipment ............................................................................ 273Cooling Towers ................................................................................... 274Steam Turbines .................................................................................. 276Electrical Equipment ......................................................................... 276

Questions ............................................................................................. 280

Contents vii

viii Contents

21. ADVANCES IN MAINTENANCE 281–293

Introduction ......................................................................................... 281Reliability and Maintenance ............................................................ 282Telematic Maintenance Services ...................................................... 282Decision Support System Based on Artificial Intelligence .......... 283Use of Radio Frequency Identification (RFID) .............................. 284Optimization of Maintenance Activities ......................................... 286Risk-based Maintenance Planning ................................................... 287Total Productive Maintenance (TPM) ............................................. 287Maintenance Management ................................................................ 288Quality Control in Maintenance ...................................................... 289Effective Maintenance Organization ............................................... 290Root Cause Analysis (RCA) .............................................................. 290Maintenance Outsourcing ................................................................. 292

Questions ............................................................................................. 293

Bibliography 295–296

Index 297–300

The exploitation of knowledge and technology has resulted in thedevelopment of complex and sophisticated equipment and machineryin every field of engineering. These high investment systems, in turn,call for their effective utilization. The responsibilities of maintenanceengineers have thus increased manifolds. They have to keep suchmachines and systems in working order to meet production targets orservice requirements.

In the Second Edition of this book, it has been our endeavour toincorporate the latest techniques and methodologies used today tomaintain the equipment and facilities at a minimum cost.

The topics such as research and development in maintenance,the role of overhauling in maintenance, and expert systems in mainte-nance have been included in the introductory chapters. Conditionmonitoring has its own significance in maintenance and this has beendealt with in this book as well. The other maintenance practices suchas maintenance scheduling, computerized maintenance planning,reliability indices, quality and reliability, reliability improvement andtesting, instrumented equipment monitoring, and so forth, which areessential for improving the life expectancy of the machinery, have alsobeen added. To optimize the maintenance costs, a maintenance auditprocedure has been incorporated. Maintenance information which is acrucial aspect in decision making is also included. The role of thelubricants is most important in maintenance function and, hence, theuse of hi-tech oils and lubricants has been discussed. Pollution alsoaffects the functions of equipment and machinery, therefore, the topicon pollution prevention has been given due importance in the book.

Safety is important in every walk of human life. Its significancein maintenance has been highlighted. The maintenance of some of theimportant electrical machines has been discussed along with themaintenance of mechanical equipment.

Decision making is an important function in any organization,which is also true in the case of maintenance. This vital aspect ofmaintenance and management has been presented in detail in thisedition. Advances in maintenance have been presented in a separatechapter.

Authors would appreciate receiving suggestions from the readersto further improve the content of the book with respect to moderndevelopments in maintenance practices.

R.C. MISHRAK. PATHAK

ix

Preface

continue

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