Modern Maintenance. Management By Jayprakash Komiya Manager (Mech)

What is Maintenance It represent a set of measures and action that ensures an equipments prevention, preservation or restoring in an anticipated state or capable to guarantee a certain services altogether with the minimizing of the maintenance cost. Modern maintenance Modern maintenance management is not to repair broken equipment rapidly. Modern maintenance management is to keep the equipment running at high capacity and produce quality products at lowest cost possible.

Until the 60’s activity of maintenance was synonyms with repairing Why to consider change in maintenance strategies: . Increasing demand of production. . Production plan changed from 16 hours production to 24 hour production . . High downtime cost of plant and equipment . To maintain/improve the quality of products

Basic cycle of maintenance Work Identification Work Planning Work Scheduling Work Execution Analysis History Recording

The basic function of a maintenance management system can be : Preventive maintenance Plant and unit record(Equipment) Inventory and spare parts control system Document record Planning system for maintenance and work order routines Technical/economic analysis of plant history, maintenance and machine availability

Types of Maintenance Corrective or Break Down Maintenance Planned or Preventive Maintenance Predictive or Condition Based Maintenance Total Productive Maintenance Reliability Centered Maintenance

Types of Maintenance Corrective Maintenance Repair it when it fails Break-down Time Cost Corrective Maintenance Repair it when it fails Preventive Maintenance Maintenance at regular intervals Time Cost Time Cost Predictive Maintenance Problem detected before predicted failure. Maintenance planned ahead

Corrective Maintenance - Break-down Maintenance - Not recommended for critical machines Corrective Maintenance leads to: Secondary damage Safety risk Unplanned downtime Unplanned maintenance Product waste Spares inventory Time Cost

Preventive Maintenance - Time-based Maintenance - Not recommended for critical machines Time Cost Time-based Preventive Maintenance involves: More frequent overhauls Risk of early failures Tampering with good machines Time consuming overhauls Experts needed for each overhaul

Predictive Maintenance Recommended for critical machines Break-down Time Cost Monitor the condition of the machine and predict when it would fail Plan maintenance ahead of time and save money Repair the machines only when they need to Focus overhauls only on faulty parts Higher plant availability, performance and reliability Greater safety Better product quality Attention to environment Longer equipment life Greater cost effectiveness

Condition Monitoring Techniques Visual Monitoring Thermography Vibration Monitoring Shock pulse Monitoring Temperature Monitoring Wear Debris Analysis Motor Current Monitoring Noise monitoring and analysis

Predictive Maintenance (PdM) and Condition Monitoring

Machinery Health Management Diagnosing a machine is just like a person: Vibration: The ‘pulse’ of the machine Oil: The ‘life blood’ of the machine Motor Current: The ‘brain waves’ of the machine Thermography: ‘Taking its temperature’ Total Picture

Vibration Analysis Mechanical faults generate vibration Apply pattern recognition and exception analysis Use expert system to screen data Fault Types Misalignment Imbalance Bearing Defects Gear Defects Looseness Belt Drive Problems Electrical Problems Cavitation

Trending Overall Vibration Vibration severity + 4 steps + 3 steps + 2 steps + 1 step Normal Inspection, minor repairs Plan major overhaul (Shutdown) Effect repairs Routine maintenance (lubrication, etc.) Vibration measurement Maintenance activities Breakdown

Shock Pulses from Bearings

Bearing & Lubrication Condition Good Bearing, Sufficient Lubrication Good Bearing, Insufficient Lubrication Damaged Bearing

Infrared Thermography-Applications Mechanical inspections Bearings Gears Belts Couplings Motor insulation breakdown Electrical equipment Bad connections, breakers, fuses Overloaded conditions Motor Control Center components Distribution lines Cable trays/conduits

Thermograph of Electrical Panel Eye - view Thermal Image

Oil Analysis Examination of lubricants provides information about: Chemical properties Ability to lubricate machine and prevent adhesion wear Contamination Presence of foreign particles that might induce wear Wear particles Evidence of wear that has already occurred

Fundamental Concept Four criteria are considered to evaluate condition: SIZE : Severity of wear SHAPE : Wear mechanism / Cause of wear COMPOSITION : Wearing component CONCENTRATION : Severity of wear

Predictive Maintenance (PdM) and Condition Monitoring

Total Productive Maintenance Total – Involves all functions and people at all levels Productive – Efficient and effective utilization of all the resources Maintenance – Keeping man-machine-material system in optimal condition. TPM can be defined as a structured equipment-centric continuous improvement process that strives to optimize production effectiveness by identifying and eliminating equipment and production efficiency losses throughout the production system life cycle through active team based participation of employees across all levels of the operational hierarchy. TPM aims at achieving Zero breakdown, Zero defect, Zero accident, and Zero pollution.

The Pillars of TPM

Reliability Centered Maintenance(RCM) Objective Maintenance strategy optimization Extension of equipment life span Elimination of chronic machine problem Root cause analysis No preventive maintenance tasks to be performed- unless it can be justified Definition a process used to determine the maintenance requirement of any physical asset in its operating context.

Reliability-Centered Maintenance (RCM)

Evaluating Consequences with an RCM Decision Diagram

Maintenance ………..Assisting tools Quality circles Suggestion schemes Continual improvement Standardizing Management Systems ISO 9001:2000 Quality Management System ISO 14001 Environmental Management System OHSAS 18001 Occupational Health and Safety

Objectives of Maintenance During the years the maintenance function has not been seen as a condition for production output. The previous approach has been that maintenance is the necessary evil, one among the cost generators in the organization. Very often the maintenance strategy in plants has been to reduce the maintenance cost as much as possible without thinking of the consequences. Objective of the maintenance is , as priority one , to create an availability performance which is suitable for production demands in the organization. No mechanized/atomized company has yet succeeded to produce with stopped equipment. Production buy availability performance from maintenance.

Changing approach of industries towards maintenance PRODUCTION RESPONSIBILITIES Basic to the philosophy of planned maintenance is the concept that production is an equal partner with maintenance in the achievement of established goals. Production has certain obligations to maintenance: 1.  Production must accept maintenance as an equal partner. 2.  Production must continually attempt to optimize production. 3. Production equipment must not be abused. Higher than designed output is not  necessarily abuse. 4.  Lines of communication between production and maintenance must remain open.

Need of Motivation for Maintenance Staff -Maintenance is a thankless job”, this is repeated by us every time and also sometimes, How to Motivate the Maintenance personnel 1. Job Satisfaction 2. Recognition 3. Job rotation/enrichment 4. Reduced stress at work

CASE STUDY: SCREENING PLANT BD PATTERN

SCREENING PLANT AVAILABILITY & BREAKDOWN

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