MEng 5251: Maintenance of Machinery

CHAPTER ONE
INTRODUCTION

October, 2023

By : Behailu Mamo

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 Content:

Introduction

Definition

History (Generation) of Maintenance

Challenge of Maintenance

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Definition:

Maintain is defined as
cause to continue (Oxford Dictionary), or

keep in an existing state (Webster Dictionary).

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 Definition Cont…

Maintenance is :

The combination of all technical and administrative

actions, including supervision actions, intended to
retain an item in, or restore it to, a state in which it
can perform a required function.

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 Definition Cont…

Maintenance is :

A set of organized activities that are carried out in

order to keep an item in its best operational
condition with minimum cost acquired.

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Maintenance activity is the systematic and scientific
upkeep of equipment for:

 prolonging life of the equipment,

 assuring instant operational readiness,

 optimal availability for production at all times, and

 making sure that safety of man and machine is at no

time jeopardized

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Maintenance Activities

 Some of the major activities of maintenance function

could be either repair or replacement activities,

which are necessary for an item to reach its
acceptable productivity condition and these
activities, should be carried out with a minimum
possible cost.

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Maintenance History

 According to John Moubray (Reliability-Centered

Maintenance), the evolution of maintenance since the
1930's can be traced through three generations based
on three technical factors:

I. growing expectations of maintenance,

II. changing views on equipment failures, and
III. changing maintenance techniques.
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First Generation

This covers the period up to the World War II.

During this period:

 industry was not highly mechanized,

 equipment was simple and over designed,

 downtime did not matter much,

 prevention of equipment failure did not have high priority,

 failures were corrected as they occur.

 As a result, there was no need for systematic maintenance

beyond cleaning, servicing and lubrication.
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Second Generation
 During the war, demand for goods increased and supply of industrial outputs was
low. This led to increase in mechanization.

During this period:

 machines became numerous and more complex,

 industry started to depend heavily on these machines,

 downtime started to matter,

 the idea that equipment failures could and should be maintained came up.

 As a result, the concept of preventive maintenance and

maintenance planning and control systems grew up.
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Third Generation:

 Since the mid-seventies, new expectations, new research and new

techniques have revolutionized maintenance.

During this period:

 maximizing life of equipment has become important,

 higher plant availability and reliability have become very important,

 greater automation has been effected,

 quality standards, safety and environmental consequences matter quite a lot,

 cost of maintenance is becoming central,

 As a result: greater expectations and leading to new research which

in turn lead to new techniques.

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 Third Generation
- Higher plant availability
and reliability
- Greater safety
- Better product quality
Second Generation - No damage to the
First Generation - Higher plant availability environment
- Fix it when it - Longer equipment life - Longer equipment life
broke - Lower costs - Greater cost effectiveness
1940 1950 1960 1970 1980 1990 2000
Growing expectations of maintenance

The three Third Generation

generation
of First Generation Second Generation

Maintenance 1940 1950 1960 1970 1980 1990 2000

Changing views on equipment failure

Third Generation
- Condition monitoring
- Design for relaibility
and maintainability
- Hazard studies
Second Generation - Small fast computers
- Scheduled overhauls - Failure modes and effects
First Generation - Systems for planning analysis
- Fix it when it and cintrolling work - Expert systems
broke - Big, slow computers - Multiskilling and teamwork
1940 1950 1960 1970 1980 1990 2000
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The Challenges of Maintenance

The challenges that modern maintenance managers face

are summarized as follows:

 to select the most appropriate maintenance techniques,

 to deal with each type of failure process appropriately,

 fulfilling the expectations of users,

 finding the most cost-effective and sustainable mode,

 getting an active support of people involved.

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Involvement of Maintenance activities
 Maintenance is related to profitability through:

 equipment output and equipment running cost.

 time taken for maintenance purposes.

 The importance of maintenance increases with

industrialization.

 The level of maintenance required at the equipment

operation stage is affected by factors at other stages

through which the equipment passes.
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 Design stage:
 Reliability and maintainability are the important factors which should be

considered properly in relation to performance of equipment, capital and running

costs.
 Installation stage:
 Maintainability is an important factor to be considered during the installation, for

it is here that maintenance problems become clear.

 Commissioning stage:
 This is a stage of technical performance testing and also a stage of where primary

design faults are located and designed out.

 Operational stage:
 The operational stage is a stage of learning where maintenance plays an important

role.
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 Equipment Life – Cycle

OPERATIONAL INVOLVEMENT

MANUFACTURE COMMISSIONING OPERATION

SPECIFICATION DESIGN REPLACEMENT
INSTALLATION
- Conceptualization - Performance - Primary design - Design fault - Wear-out
- Reliabilty - Quality control fault control detection - Obsolescence
- Maintainability - Design fault - Technical - Maintenance
- Support system detection performance test optimization
- Maintainability - Maloperation
avoidance

LEARNING PERIOD

CONTINUAL FEEDBACK

Fig. 1.2 Equipment life-cycle

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Maintenance Management
 is the direction and organization of resources in order to control the

availability and performance of an industrial plant to a specified

level.

 In maintenance management the problem is two-dimensional:

 Determination of size and nature of the maintenance work load,

 Organization and control of labour, spares and equipment to

meet the workload.

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Function of maintenance work

 Earlier the objective of maintenance function was

considered to optimize plant availability at minimum cost.

 Today it is being considered as "Maintenance affects all

aspects of business effectiveness and risk-safety,

environmental integrity, energy efficiency, product quality
and customer service, not just plant availability and cost."

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 The maintenance department influences plant availability directly

through preventive and corrective maintenance.

The most basic definition of availability is

Top
Availability 
Top  Tdown
where Top = cumulative time of operation

Tdown = cumulative outage time

Tdown = Down time = repair time + delays

Repair time = f(maintainability, management method, engineering techniques)

Delays = f(organization of maintenance resources and information)

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 Equipment Time EQUIPMENT TIME

ACTIVE TIME INACTIVE TIME

UPTIME DOWNTIME

MAINTENANCE MODIFICATION DELAY

PM TIME CM TIME

PROCUREMENT FAULT
PREPARATION CLEANUP
TIME CORRECTION
TIME TIME
TIME

ISOLATION ADJUSTMENT CHECKING LOGGING AND

TIME CALIBERATION TIME RESTORATION
TIME TIME

REPAIR IN REMOVE REMOVE AND REPAIR

PLACE REPLACE-REPAIR WITH A LIKE ITEM

INSPECTION SERVICING REPLACING MINOR OVERHAUL MAJOR OVERHAUL

TIME TIME TIME TIME TIME
20 (aging units)
 Equipment Down Time

DOWNTIME

CM PM DELAYS
(Repair Time) (Off-line Time) (Waiting for M)

RESOURCES INFORMATION

MAINTAINABILITY MANAGEMENT ENGINEERING TECHNIQUES

(Logical fault-finding: Diagnostics)

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 Objectives of Maintenance:

 Maintenance purposes, functions and objectives are inter-related and are

overlapping to some extent. From the various aspects and paragraphs

mentioned earlier in this chapter, maintenance objectives for an industry can
be the followings:

 To maintain plants and equipment's at its maximum operating

efficiency, reducing down times and ensuring operational safety;

ensure maximum availability of plant, equipment and

machinery for productive utilization through planned

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maintenance
 To safeguard investments by minimizing rate of
deterioration and achieving this at optimum cost through
budgeting and controls; maintain plant equipment, and
facilities at an economic level of repairs at all times, to
conserve these and increase their life-span

 To help management in taking decisions on replacements

or new investments; and actively participate in

specification preparation, equipment selection, its erection
and commissioning etc,
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  Help in implementation of suitable procedures for procurement,

storage and consumption of spares, tools and consumables etc

(inventory control etc)

 Standardization of spares and consumables, in conformity with

plant, national and international standards and help in adoption

of these standards by all users in the plant

 Running of captive workshops for repairs and conditioning and

also for making some new spares; etc.

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 Thank you
If you have any questions ???

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 Question? 10%

 Why do we need maintenance?

 What are the costs of doing maintenance?

 What are the costs of not doing maintenance?

 What are the challenge of maintenance?

 How can maintenance affect profitability of company?

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