PLANT MAINTENANCE SANDAMALI W.D.
G
161037H
To achieve minimum breakdown and to keep the plant in good working condition at the lowest possible cost and ensure long life time of the machines
Plan and schedule Perform the maintenance activities in
maintenance work-prevent a most economical manner.-reduced Maintenance schedule should:
interruptions in operations. Need for subcontracting workers, no Clear, precise and easy to operate. Example:
need rescheduling of production Scheduling Based upon accurately determined time standards. Can be carried out during lunch hours, between shifts or at weekends etc.
of Plant Finalized in consultation with the production department Take advantage of planned machine stoppages
Maintenance Creating with a balanced workload Plan major repairs and overhauls during holidays,
Objectives and Maximize of the amount time need Flexible Make use of reserve plant if the need arises.
importance for complete the goals- reduced loss
in production time and over-time.
1. Master maintenance schedule:
Preserve the value of assets by Perform the activities of inspection, adjustments,
Tools: Procedure: Considers total man-hours and the manpower needed for task
repairs, replacements and operation of the shops The distribution of jobs (reasonable man loadings)
reducing the rate at which they
performing the various jobs. Visual charts
deteriorate Scheduling boards Accommodate unanticipated tasks and jobs.
Individual cards Breaking overall time spans allocated under the master schedule.
Disadvantages: 2. Detailed weekly or daily schedule
Breakdowns generally occur at unsuitable times. Properties: Provides information about tasks to be carried on each job for each day in the coming week.
Reduction of production. Justified in small factories. Requires records of work capacity of each section of the maintenance department
Faster machine deterioration. Economical for equipment whose down-time Procedure of PM Flexible and able to accommodate emergency jobs.
Less safety to both workers and machines. nnand repair costs are less Who should do PM Issued to concerned persons every day or near the weekend
More spoilt material. Little administrative work, few records and a Where and when
Direct loss of profit. hhsmall staff What to inspect for?
How often (inspect-frequency)?
How to schedule?
Steps: Typical Causes of Equipment Breakdown: Preventive maintenance records
Fault detection Failure to replace worn out parts. Spare parts
Fault isolation Lack of lubrication. Storing
Fault elimination Neglected cooling system. Maintaining control of the PM programed
Verification of fault elimination. Indifference towards minor faults.
Advantages: Advantages:
Reduced breakdowns and connected down-time. Elimination of delays
Lesser odd-time repairs and reduced overtime. Improved supervisory controls
(c) Preventive maintenance Greater safety for workers. Determination of labor content-proper
Fewer large-scale and repetitive repairs. gcoordination of craftsmen
(a). Corrective or breakdown maintenance. Set of activities to prevent the
Low maintenance and repair costs. Work backlogs can be planned
failure of plant equipment,
Repairs are made after the equipment is failed. machinery and system
Objectives:
Types of Maintain the value of equipment
Plant Maintain the optimum productive efficiency of equipment Types:
Maintenan Maintain the operational accuracy Time standards
Maximum production at minimum repair cost Lubrication standards
(b) Scheduled maintenance ce
Involve: Ensure safety
A planned procedure aimed at avoiding Periodic inspection Standard
breakdowns which included in the (d) Predictive maintenance Upkeep of plant equipment Data for
predetermined schedule. Setting and Using Standard Data: Plant
A set of activities that detect changes The technical study is required to assemble standard data
Maintenance
in the physical of the equipment Standard data derived from time studies (the most widely used system)
Bad for an individual factory with more time need
There are management consulting firms for established programmers to
Incorporate hhclients for installation of maintenance controls.
Cleaning
Sensitive instruments: Properties:
Lubrication
Audio gauges, Unusual sounds/excessively hot cables/vibrations predict troubles. Maintenance standards are used for:
Part replacement
Vibration analyzers, Hand touch can point out many unusual (equipment) conditions. Planning and scheduling maintenance work
Repair
Ultra-sound detectors Measured periodically or on a continuous basis (it help to Providing fair number of personnel
Overhaul equipment
Pressure, temperature and equipment adjustments, repair or overhaul). Measuring the output of performance of maintenance men
sresistance strain gauges Extends the service life of equipment without fear of failure. Providing incentive earnings for maintenance men
Maintaining control of the PM programed:
Measures should be taken:
Periodic review of PM programed with the operating department.
Review of monthly reports of PM inspections. Storing
Analytical approach to the evaluation of PM. Spare parts should have a stamped code number.
The stock card may be identified by this number.
Who should do PM The bin or rack, in which the part is lying, should have its location reference number recorded on the
Depend on size, age, location, machinery wwstock card.
Production Department Spare parts for one equipment may be grouped together and referred to by their plant number.
Maintenance Department. For locating a part, the store keeper would first check the stock card bearing the plant number and
Separate division wwtake down the bin reference number.
Depends upon:
The past experience.
Advice from equipment manufacturers.
Where and when The cost of buying and storing the spares.
PM is costly, Apply to those key items which are more essential The cost of having idle plant waiting for spare parts in case of a breakdown or
Examples: wwat the time of need
Material handling equipment The ease or difficulty with which the spare parts can be made available when
Safety equipment wwrequired.
Procedure of PM Whether spare parts are standard or not
Process equipment
Water, air and fuel lines 1. Who should do PM
2. Where and when
3. What to inspect for?
Spare parts
4. How often (inspect-frequency)?
Spare parts are stored in order to reduce the loss
5. How to schedule?
of production time.
6. Preventive maintenance records
What to inspect for 7. Spare parts
Listing the equipment 8. Storing
Decide what physical parts of equipment needs attention (with manual 9. Maintaining control of the PM
issued by the equipment manufacturer) programed
Equipment maladjustments (Identified by the craftsmen and supervisors)
Making the list of machines and their parts needing PM
Make a CHECK-LIST to ensure that no inspection point has missed. Preventive maintenance records:
Reliable guides for measuring the effectiveness
How to schedule Determining frequency of inspections.
Inspection dates & types Preparing maintenance schedules.
Lowest overall cost Predicting equipment life.
How often (inspect-frequency) Classified-inspection and service functions
Exception is safety standards & Over-inspection is needless Routine upkeep
Past experience Periodic inspections Records should show
On the basis of costs and savings of the PM program Contingent Type of equipment and its description.
Service and hours of operation
Whether it is a key item?
Age, condition and value of the equipment
Name of the manufacturer.
Safety requirements and health hazards Routine or periodic inspections may be scheduled as: Cost and date of purchase of the equipment.
Exposure of equipment to dirt, friction, fatigue, stresses, Do them in the day-shift Location of the equipment in the factory
corrosion, vibrations, overloading Spread them over the year to even up the total work load of maintenance.
Plan them when equipment is not producing
Ensure that PM consumes least productive time.
