All about the maintenance management in an Organization

1. Maintenance
Management

2. Introduction
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.

3. Meaning of Maintenance &
Maintenance Management
 Maintenance is defined as “any action that restores
failed units to an operational condition or retains non-
failed units in an operational state”.
 Maintenance Management is concerned with the
direction and organization of resources in order to
control the availability and performance of industrial
plant to some specific level.

4. Objective of Maintenance
 Minimizing the loss of productive time because of
equipment failure.
 Minimizing the repair time and repair cost.
 To keep all productive assets in good working
condition.
 Efficient uses of maintenance personnel and
equipment.
 To improve the quality of the products and to improve
productivity.
 To maximize efficiency and economic in production
through optimum use of facilities.

5. Importance of Maintenance
Management
 Dependability of services
 Quality Assurance
 Help in not Loosing Market Share
 Cost Context Induction
 Organizations depend upon Equipment

6. Types Of Maintenance
 There are 4 models are available-
1. Breakdown/Corrective Maintenance
2. Preventive Maintenance
3. Predictive Maintenance/Condition
Maintenance

7. Types Of Maintenance
 Preventive Maintenance:
Periodic inspection is carried out to anticipate
breakdowns and to prevent them before they occur,
instead of allowing the breakdown to happen and then
to take action.
 Breakdown Maintenance:
It occurs, when there is a work stoppage because of
machine breakdown. In this sense maintenance become
repair work.
Repair are made after the equipment is out of order.

8. Types of Maintenance
Total Cost
Breakdown
Maintenance
Cost
Preventive
Maintenance Cost
Cost
Level of Maintenance Activity

9. Total Productivity Maintenance
 TPM is a way of organizing maintenance to support
productivity & quality through increased equipment
efficiency and to reduce costs.
 TPM concept means that all employees work in small
groups to maximize the improvement of equipment
efficiency.
 Operators are working independently with all
maintenance activities of their own equipment and
have also the total responsibility of operation and
maintenance.

10. Objective of TPM
 Avoid wastage in a quickly changing economical
environment.
 Producing goods without reducing product quality
 Reduce Cost
 Produce a low batch quantity at a earliest possible
time.
 Goods send to the customers must be non-defective.

11. Need For Replacement
There are two basic reason for replacement of machine:
 First and foremost is safety.
 Another legitimate reason for replacing equipment is
that it is no longer cost effective to maintain.
 The machine are to be periodically replaced.
 The replacement study can be classified into two
categories:
• Deterministic types of items that deteriorate with
time[Replacement due to gradual failure]
• Simple probabilistic model for items which fail
completely[Replacement due to sudden failure]

12. Simple Probability Model
 Electronic items like transistors, resistors, tube lights
bulbs, etc. will fail all of sudden.
 Failure of these causes complete breakdown of the
system.
 Few policies are considered for these kind of
replacements.
I. Individual Replacement Policy
II. Group Replacement Policy

13. Replacement Policies
 Individual Replacement Policy
If a particular light is beyond repairs, then it is replaced.
This kind of policy of replacement is called as
‘replacement of items as-and-when they fail’ or
‘Individual Replacement’.
 Group Replacement Policy
There are certain items which do not deteriorate but fail
completely after certain amount of use. These kinds of
failures are analyzed by the method called as group
replacement theory. Here, large numbers of items are
failing at their average life expectancy.

14. Reliability Performance
The ability of an item, under stated
Conditions of use, to perform a required
Function under stated conditions for a
stated period of time.

15. Computerized Maintenance
Management System(CMMS)
 A CMMS software package maintains a computer
database of information about an organization’s
maintenance operations, i.e. CMMIS – computerized
maintenance management information system.
 This information is intended to help maintenance
workers do their jobs more effectively (for example,
determining which machines require maintenance
and which storerooms contain the spare parts they
need).
 To help management make informed decisions (for
example, calculating the cost of machine breakdown
repair versus preventive maintenance for each
machine, possibly leading to better allocation of
resources).
 CMMS data may also be used to verify regulatory
compliance.

16. CMMS

17. CMMS

18. CMMS

19. CMMS Chart