Project Maintenance

Chapter - 9
“A stitch in time saves nine”
 Maintenance Basics

• Maintenance includes the repair or preservation of an existing

facility to prevent that facility’s deterioration to an unsafe or
irreparable state, or which involves the treatment of an existing
facility to meet acceptable standards of operation or aesthetic
quality.
• A project may keep on functioning well for its design period
unless any defects or problems come before it.
• For this, Some activity may be to bring back the system to its
original functional status from that of undesirable
nonfunctional one.
• So the maintenance of a project is the activity required to
check the probable damages or to correct any deficiencies
cropped upon in the system.
 Terminologies
• Repair:
• Repair is the process of restoring something is damaged or
deteriorated or broken, to good condition

• Rehabilitation:
• Rehabilitation is the process of returning a building or an
area to its previous good conditions

• Maintenance:
• Maintenance is the act of keeping something by checking
or repairing it regularly

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Importance of Maintenance
In any engineering project, the errors and problems are
accumulated unless regular and timely maintenance is
carried out. The maintenance prevents the following
consequences
• System deterioration
• Reduces services and problems in management
• Poor project operation
• Frequent and costly rehabilitation
• Long production time
 Objectives of Maintenance
• To increase the economic life of the infrastructure/system and to provide easy
operation with optimum service/ production /supply. Also to reduce risk and
mitigates the disaster.
• To maximize the availability and reliability of all assets, especially a system
plant, equipment and machinery and to obtain a maximum possible return on
investment
• To extend the life of assets by minimizing wear and tear and deterioration
• To ensure operational readiness of all equipment required for emergency use
at all time such as standby units, firefighting units, and rescue units.
• To ensure the safety of personnel using equipment/facilities
• To minimize the frequency and severity of interruptions to the operating
process.
• To plan and schedule maintenance work
• To increase the reliability of the system
 Types of Maintenance : Process of Maintenance

Maintenace

Planned maintenace Unplanned maintenace

Preventive Corrective

Running Shutdown Breakdown Em ergency

 Preventive Maintenance
• Maintenance carried out at predetermined or at scheduled
intervals, or to other prescribed criteria, and intended to
reduce likelihood of an item not meeting an acceptable
condition.
• Involves regular, routine cleaning minor repair works to
avoid major repair works at later stage.
• An important aspect of preventive maintenance is
participation and commitment of users.
 Corrective Maintenance

• Maintenance carried out to restore (including

adjustment and repair) an item which has ceased to
meet an acceptable condition.
• Includes the activities of major repair works.
• Required due to the ageing, calamities, natural disaster
or damage caused by users or public.
• Requires high investment and qualified technicians to
overcome the problem.
Types of Corrective Maintenance

• Roof repair (cracks, broken, leakage or seepage)

• Slab repair (cracks, broken, leakage or seepage)
• Walls repair (broken, cracks, leakage, seepage)
• Floor repair (settlement, cracks, broken, leakage or
seepage)
• Door Windows (Cracks, broken)
 Steps for Corrective Maintenance

Problem identification and categorisation

Preparation of cost estimate

Approval process of maintenance work

Service procurement & contractual process

Corrective maintenance work

Prepare work done documents reports

Get the approval for completed work

Clear account expenses

 Emergency maintenance

• Unplanned maintenance where maintenance works is caused by

an unforeseen breakdown or damage.
• Emergency works arise unexpectedly but they must be solved
instantly otherwise it may cause great damage to the system of
the project.
• So this is a special type of maintenance which includes the
repairing works of damages caused by major disasters
 Distinction of maintenance and repair activities

Activities Maintenance Repair

Painting work 
Mending a broken water supply pipe 
Preventing vegetation from growing on the

walls and roofs
Changing broken tiles on the floor 
Adding lean concrete to the existing

leaking roof
Servicing of water pumps and oiling 
Cleaning of drainage 
Tightening loose screws on doors and

windows
Changing broken panes on door and

windows
 Maintenance Planning and Scheduling

WHY WE DO FAIL
Reasons Why Maintenance Planning is Not Effective
• We don’t know what good planning looks like (We don’t practice this in a
regular basis
• We don’t separate the maintenance planning and maintenance scheduling
• We think it is all about the planner/scheduler, and rest of us can still be
reactive
• Preventive maintenance is conducted and yet failures continue !
• No focus, or little focus on prevention or identification of failure modes !
• Responsibility assignment (focal point)
• Inventory/Store Management
• Procurement Management
Lack of proper Records !!
Specially for the medical and other equipment !!!
 Factor involved in Maintenance
Planning
• Administrative
Priority accorded to maintenance in the overall management
Processes and procedures used to carry out maintenance activities
Management and technical ability of those responsible
• Financial
Budget allocation from the Financial Year Budget Appropriation
Assistance from non-government sources
Cost of labor and materials
• Technical
Design, age and condition of facilities
Nature and standard of past maintenance work done
• Resources
Availability of competent workmen and appropriate materials
 Planning and Scheduling Objectives

• Minimizing the idle time of maintenance workers.

• Maximizing the efficient use of work time, material, and
equipment.
• Maintaining the operating equipment at a responsive level to the
need for production in terms of delivery schedule and quality.
• An essential part of planning and scheduling is to forecast future
work and to balance the workload between these categories.
• The maintenance management system should aim to have over
90% of the maintenance work planned and scheduled.
 Maintenance Planning
Planning is the process by which the elements required to perform a task
are determined in advance of the job start. Good planning is a
prerequisite for sound schedule. It comprises all the functions related to
the preparation of:
• The work order
• Bill of material
• Purchase requisition
• Necessary drawings
• Labor planning sheet including standard times
• All data needed prior to scheduling and releasing the work order.
Maintenance Planning
 Planning Procedures
• Determine the job content.
• Develop a work plan. This entails the sequence of the activities in the job
and establishing the best methods and procedures to accomplish the job.
• Establish crew size for the job.
• Plan and order parts and material.
• Check if special tools and equipment are needed and obtain them.
• Assign workers with appropriate skills.
• Review safety procedures.
• Set priorities for all maintenance work.
• Assign cost accounts.
• Complete the work order.
• Review the backlog and develop plans for controlling it.
• Predict the maintenance load using effective forecasting technique.
 Basic Levels of Planning Process
• Long-range planning: it covers a period of 3 to 5 years and
sets plans for future activities and long-range improvement.
• Medium-range planning: it covers a period of 1 month to 1
year.
• Short-rang planning: it covers a period of 1 day to 1 week. It
focuses on the determination of all the elements required to
perform maintenance tasks in advance.
 Maintenance Scheduling
• It is the process by which jobs are matched with resources and sequenced
to be executed at a certain point in time.
• Scheduling deals with the specific time and phasing of planned jobs
together with the orders to perform the work, monitoring the work,
controlling it, and reporting on job progress.
• Successful planning needs feedback from scheduling.

Maintenance Schedule Can be Prepared at Three Levels

• Long-range (master) schedule
• Weekly schedule
• Daily schedule
Maintenance Cost
To carry out maintenance activities some direct cost are evolved. The investment indirect
cost results from the sound operation of plant and machinery that minimizes failure cost. It is
always recognized that the direct cost involved in regular maintenance is very less compared
to the resulting failure cost due to a breakdown of the machine if maintenance is not carried
out in time.
COST

BREAKDOWN COST

OPTIMAL MAINTENANCE
COMMITMENT
Direct cost / Preventive Maintenance cost
These are the actual cost involved in the maintenance of the plant. It is
quantifiable and measurable. This includes:
a. Regular maintenance cost
b. Labor cost
c. Equipment, parts and components costs
d. Stock management cost
e. Training and technological updating costs
Indirect cost/ Cost of Failure
These are failure cost. They are not directly measurable in terms of money, but they
cause heavy financial loss to the organization. Some of them are summarized as
follows:
a. Loss of production and service
b. Alternation in the quality of products and services
c. Delivery delays
d. Deterioration in workplace and environment
e. Loss of goodwill and image
f. Depression in employees etc.
Maintenance Management Cycle
 Maintenance Management Process

Tasks, Frequencies
Asset inventory and Task times

Work schedule

Work orders
Costs:
1. Labor
2. Equipment
3. Material Maintenance Source of
4. Contract budget funds