Maintenance Engineering

(Ch. E 405)

Izzat Iqbal Cheema

Lecturer
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Maintenance
All activities that maintain facilities and equipment in good working order so that a system can perform as intended.

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Maintenance
It is consider as a combination of actions carried out in order to replace, repair, service (or modify) the components, or some identifiable grouping of components, of a manufacturing plant so that it will continue to operate to specified availability for specified time.
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Function of Maintenance
The function of maintenance is the control of plant availability.
Time of operation Availability Time of operation Outage time

Availability

Mean running time to failure ( MTTF ) Mean running time to failure ( MTTF ) Mean time to repair ( M )

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Maintenance Categories
Buildings and Grounds Equipment Maintenance

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Reasons for Maintenance

Avoid production disruptions Not add to product cost Maintain high quality Avoid missed delivery dates Increase in equipment life Hazards to employees + environment avoid Placebo
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Types of Maintenance
1. Breakdown Maintenance 2. Preventive Maintenance
Periodic Maintenance Predictive Maintenance

3. Corrective Maintenance 4. Maintenance Prevention

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Decision Makers: Trade-off

Total Cost Maintenance Cost

Breakdown & Repair Cost Preventive Optimum Maintenance Cost Amount of Maintenance

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Types of Maintenance
Breakdown Maintenance Preventive maintenance
o Periodic maintenance o Predictive maintenance

Corrective maintenance Maintenance prevention

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Breakdown Maintenance
It means that people wait 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.

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Preventive Maintenance
It is a daily maintenance ( cleaning, inspection, oiling and re-tightening ), design to retain the healthy condition of equipment and prevent failure through the prevention of deterioration, periodic inspection or equipment condition diagnosis, to measure deterioration. It is further divided into periodic maintenance and predictive maintenance. Just like human life is extended by preventive medicine, the equipment service life can be prolonged by doing preventive maintenance.
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a. Predictive Maintenance
This is a method in which the service life of important parts are predicted based on inspection or diagnosis, in order to use the parts to the limit of their service life. Compared to periodic maintenance, predictive maintenance is condition based maintenance. It manages trend values, by measuring and analyzing data about deterioration and employs a surveillance system, designed to monitor conditions through an on-line system.
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b. Periodic Maintenance
Time based maintenance consists of periodically inspecting, servicing and cleaning equipment and replacing parts to prevent sudden failure and process problems.

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Corrective Maintenance
It improves equipment and its components so that preventive maintenance can be carried out reliably. Equipment with design weakness must be redesigned to improve reliability or improving maintainability.

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Maintenance Prevention
It indicates the design of new equipment. Weakness of current machines are sufficiently studied ( on site information leading to failure prevention, easier maintenance and prevents of defects, safety and ease of manufacturing ) and are incorporated before commissioning a new equipment.

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Consequences of Breakdown
1. 2. 3. 4. 5. 6. 7. 8. Production capacity is reduced Orders are delayed There is no production Overhead Continues Increasing the cost per unit Quality issues Safety issues Environmental issues
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Breakdown Maintenance
It is to deal with the problems after they have taken place.
Reactive Approach

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Preventive Maintenance
It is to deal with the problems through certain programs.
Proactive Approach Examples:
Lubrication Adjustment Cleaning Inspection and replacement of worn parts

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Decision Makers: Trade-off

Total Cost Maintenance Cost

Breakdown & Repair Cost Preventive Optimum Maintenance Cost Amount of Maintenance

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Concepts of Preventive Maintenance

Goal: To reduce the incidence of breakdowns or failures in the plant or equipment to avoid the associated cost. Costs: Loss of outputs, idle works, schedule disruptions, injuries, damage, products or facilities, repairs. Periodic: Scheduled according to maintenance personnel and avoid interference with operating hours.

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Scheduling of Preventive Maintenance

Results; planned inspection Calendar; passage of time No. of operating hours

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Example - 1
The frequency of breakdown of a machine per month is shown in the table. Cost of a breakdown = $ 1,000 / month Cost of preventive maintenance is $1,250 / month Manager should do preventive maintenance, or would it be cheaper to repair the machine when it breaks down?
Number of breakdowns Frequency of occurrence 0 0.20 1 0.30 2 0.40 3 0.10

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Example 1 (Solution)
No. of Breakdowns 0 1 2 3 Frequency of Occurrence 0.20 0.30 0.40 0.10 1.00 Expected No. of Breakdowns 0 0.30 0.80 0.30 1.40

Breakdown cost = 1.40 x 1000 = $ 1,400 / month Savings = $ 150 / month (Preventive Maintenance)
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Problem - 1
The probability that equipment used in hospital lab will need recalibration is given in the following table;
No. of recalibration Probability of occurrence 0 0.15 1 0.25 2 0.30 3 0.20 4 0.10

A service firm is willing to provide maintenance and provide any necessary calibrations for free for a fee of $ 650 per month. Recalibration costs $ 500 per time. Which approach would be most cost effective, recalibration as needed or the service contract?
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Predictive Maintenance
It is an attempt to determine when to perform preventive maintenance activities.
Historical Data:
Installation, operating hours, dates, types of insurance and types of repairs.

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Approaches used to deal with breakdowns

1. 2. 3. 4. Standby or backup equipment Inventories of spare parts Operators based minor repairs Repair people

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Replacement
What is the cost of replacement compared with the cost of continued maintenance? Technology change Forecasts of demand

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Example - 2
The average time before breakdown is normally distributed and has a mean of 3 weeks and a standard deviation of .60 weeks. If breakdown cost averages $1,000 and preventive maintenance costs $250, what is the optimal maintenance interval?

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Example 2 (Solution)
Pr eventiveCost 250 0.20 Pr eventiveCost Breakdown Cost 250 1000 t mean z S .D.

From Appendix Table B; z = - 0.84

t mean z ( S .D.) 3 0.84(0.60) 2.5 weeks
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Problem - 2
The frequency of breakdown of machine that issues lottery tickets is given in the following table. Repairs cost an average of $240. A service firm is willing to provide preventive maintenance under either of two options. #1 is $500 and covers all necessary repairs for free, and #2 is $350 and covers any repairs after the first one, for free, provide any necessary repairs. Which option would have the lowest expected cost, pay for all repairs, service option #1, or service option #2?
No. of breakdowns/month Frequency of occurrence
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0 0.10

1 0.30

2 0.30

3 0.20

4 0.10
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Problem - 3
Determine the optimum preventive maintenance frequency for each of the pieces of equipment if breakdown time is normally distributed:
Equipment A 201 B 400 C 850 Equipment A 201 B 400 Average Time (days) between Breakdowns 20 30 40 Preventive Maintenance Cost ($) 300 200 Standard Deviation 2 3 4 Breakdown Cost ($) 2,300 3,500

C 850
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4,800
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