PowerPoint Presentation

Fleet Maintenance Management1MV 7121Col (Prof) James K Varkey24-03-2015

Syllabus

Introduction to Fleet MaintenanceTheory of Failure and ReliabilityMaintenance Operation and ControlVehicle and Equipment Replacement StrategyVehicle Maintenance Policy and StrategyVehicle Maintenance ProgrammeVehicle Maintenance PlanningMaintenance ProductivityImplementation Steps of PMComputerized Vehicle Maintenance ManagementTotal Productive MaintenanceReliability Cantered Maintenance

Fleet Maintenance Management2Fleet Maintenance Management3Vehicle Maintenance Policy and Strategy Integrated logistics support concept Types of maintenance Stages of maintenance Maintenance on the move Decentralized maintenance detachments Repair of a vehicle when battle casualty Mine Causality Repair TeamRevisionFleet Maintenance Management4Vehicle Maintenance Program Elements of planned maintenance Plan administration Facility inventory Identification of equipment Facility register Maintenance schedule Job specification Maintenance program Program controlFleet Maintenance Management5Vehicle Maintenance ProgramElements of planned maintenanceIntroductionThe main objective of maintenance management is to increase availability at minimum costs. It is said that every maintenance intervention scheduled earlier or later than the optimal time increases the maintenance cost

As we have seen, on the one hand an excess of maintenance activity implies high total costs, on the other hand a scarce maintenance activity determines a higher probability of failure and, hence, greater total cost due to emergency interventions.

Therefore, in order to select the best maintenance policy to perform an attentive analysis of the failure mode, of the consequential costs, and of operational convenience and practicality should be carried out.

Breakdown maintenance is convenient when the cost of failure is low, the cost of maintenance is high, and the rate of failure does not increase with time. On the contrary, preventive maintenance or corrective maintenance should be chosen when the cost of failure is high and the rate of failure increases with time. Fleet Maintenance Management6Vehicle Maintenance ProgramElements of planned maintenancePlan AdministrationAs for the costs of the different maintenance policies, the administration should take into account not only visible costs, such as labour, materials, services, and maintenance overhead costs, but also hidden costs, which are more difficult to detect and measure, such as operational interruption losses, time losses and customer dissatisfaction.

The difficulty of carrying out costs and benefits analysis for the different maintenance policies, considering both visible and hidden costs and their effects on vehicle availability, points out the need of maintenance administration for planning and control systems that support them in the policy design process. Such activity should help maintenance administration to evaluate the effects of the different policies on the performance of the maintenance system as a whole.Fleet Maintenance Management7Vehicle Maintenance ProgramElements of planned maintenance Plan AdministrationThe feedback loop analysis should focus on four correlated areas:- fleet management,- maintenance scheduling,- maintenance capacity management,- service management.For each of the four administrative areas identified above are the related policy levers and the administration should analyze their impact on the performance of the maintenance system by also considering financial and inventory aspects and service quality indicators.Fleet Maintenance Management8Vehicle Maintenance ProgramElements of planned maintenanceMaintenance plan and Schedule:

A document that outlines the management and technical procedure to be employed to maintain the vehicles and equipment; usually describes facilities, tools, schedules, and resources.Fleet Maintenance Management9Vehicle Maintenance ProgramElements of planned maintenance

A maintenance department is expected to perform a wide range of functions including: Planning and repairing vehicles and equipment to acceptable standards. Performing preventive maintenance; more specifically, developing and implementing a regularly scheduled work program for the purpose of maintaining satisfactory vehicle/equipment operation as well as preventing major problems. Preparing realistic budgets that detail maintenance personnel and material needs. Managing inventory to ensure that parts/materials necessary to conduct maintenance tasks are readily available. Keeping records on equipment, services, etc.Fleet Maintenance Management10Vehicle Maintenance ProgramElements of planned maintenance Developing effective approaches to monitor the activities of maintenance staff. Developing effective techniques for keeping operations personnel, upper-level management, and other concerned groups aware of maintenance activities. Training maintenance staff and other concerned individuals to improve their skills and perform effectively. Reviewing plans for new facilities, installation of new equipment, etc. Implementing methods to improve workplace safety and developing safety education-related programs for maintenance staff. Developing contract specifications and inspecting work performed by contractors to ensure compliance with contractual requirementsFleet Maintenance Management11Vehicle Maintenance ProgamElements of Planned Maintenance. One of the first considerations in planning a maintenance organization is to decide whether it is advantageous to have a echelon based maintenance system. Generally for defence services an echelon based system serves well. Some of the benefits echelon maintenance are as follows:Benefits More efficient compared to centralized maintenance Fewer maintenance personnel required More effective line supervision Greater use of special equipment and specialized maintenance persons Permits procurement of more modern facilities Generally allows more effective on-the-job training.Fleet Maintenance Management12Vehicle Maintenance ProgramElements of planned maintenance A nine-step approach for managing a maintenance schedule effectively is presented below: Identify existing deficiencies. Set maintenance goals. These goals take into consideration existing deficiencies and identify targets for improvement. Establish priorities. Establish performance measurement parameters. Develop a quantifiable measurement for each set goal. Establish short- and long-range plans. Document both long- (yearly)and short-range (monthly) plans and forward copies to all concerned.Fleet Maintenance Management13Vehicle Maintenance ProgramElements of planned maintenance Implement plan. Report status. Preparing report periodically and forward it to all concerned. The report should contain each objective identified and scheduled and potential slippage of the schedule and associated causes. Examine progress at Regular Intervals.Review progress at the end of each year with respect to stated goals. Develop a new plan for the following year by considering the goals identified in the long-range plan and adjustments made to the previous years planned schedule, resources, costs, and so on.Fleet Maintenance Management14Vehicle Maintenance ProgramElements of Planned Maintenance

Maintenance Policy and Program

A maintenance policy is one of the most important elements of effective maintenance management. It is essential for continuity of operations and a clear understanding of the maintenance management program, regardless of the size of a maintenance organization.

Usually, maintenance organizations have manuals containing items such as policies, programs, objectives, responsibilities, and authorities for all levels of supervision, reporting requirements, useful methods and techniques, and performance measurement indices. Fleet Maintenance Management15Vehicle Maintenance ProgramElements of Planned Maintenance Material Control, Facility and Inventory

Past experience indicates that, on average, material costs account for approximately 30 to 40% of total direct maintenance costs.

Efficient utilization of personnel depends largely on effectiveness in material coordination. Material problems can lead to false starts, excess travel time, delays, unmet due dates, etc. Steps such as job planning, coordinating with purchasing, coordinating with stores, coordination of issuance of materials, and reviewing the completed job can help reduce material related problems.Fleet Maintenance Management16Vehicle Maintenance ProgramElements of Planned MaintenanceJob Specification

A work order and job specification authorizes and directs the maintenance agency to perform a given task. A well-defined work order and job specification system should cover all the maintenance jobs requested and accomplished, whether repetitive or one-time jobs. The work order system is useful for management in controlling costs and evaluating job performance.

Although the type and size of the work order can vary from one maintenance organization to another, a work order should at least contain information such as requested and planned completion dates, work description and its reasons, planned start date, labor and material costs, item or items to be affected, work category (preventive maintenance, repair, installation, etc.), and appropriate approval signatures.Fleet Maintenance Management17Vehicle Maintenance ProgamElements of Planned MaintenanceEquipment Records/ Register

Equipment records play a critical role in effectiveness and efficiency of the maintenance organization. Usually, equipment records are grouped under four classifications: maintenance work performed, maintenance cost, inventory, and parts replaced. The maintenance work performed category contains chronological documentation of all repairs and preventive maintenance (PM) performed during the items service life to date. The maintenance cost category contains historical profiles and accumulations of labor and material costs by item.Equipment records are useful when procuring new items/equipment to determine operating performance trends, troubleshooting breakdowns, making replacement or modification decisions, investigating incidents, identifying areas of concern, performing reliability and maintainability studies, and conducting life cycle cost and design studies.Fleet Maintenance Management18Vehicle Maintenance ProgamElements of planned maintenanceMaintenance Schedule and Job SpecificationJob planning is an essential element of the effective maintenance management. A number of tasks may have to be performed prior to commencement of a maintenance job like: Procurement of parts, Tools, and materials, Coordination and delivery of partsIdentification of methods and sequencing, Coordination with other departments, Manpower detailing Securing safety permits.Fleet Maintenance Management19Vehicle Maintenance ProgramMathematical Model for Optimum Preventive MaintenancePreventive Maintenance (PM) is an important component of a maintenance activity. Within a maintenance organization it usually accounts for a major proportion of the total maintenance effort.

PM may be described as the care and servicing by individuals involved with maintenance to keep vehicle/equipment in satisfactory operationalstate by providing for systematic inspection, detection, and correction ofincipient failures either prior to their occurrence or prior to their development into major failure.

Some of the main objectives of PM are to: enhance capital equipmentproductive life, reduce critical equipment breakdowns, allow better planning and scheduling of needed maintenance work, minimize production losses due to equipment failures, and promote health and safety of maintenance personnel.

Fleet Maintenance Management20Vehicle Maintenance ProgramMathematical Model for Optimum Preventive Maintenance

Fleet Maintenance Management21Vehicle Maintenance ProgramMathematical Model for Optimum Preventive Maintenance

1. Inspection: Periodically inspecting materials/items to determine their serviceability by comparing their physical, electrical, mechanical, etc., characteristics (as applicable) to expected standards2. Servicing: Cleaning, lubricating, charging, preservation, etc., of items/ materials periodically to prevent the occurrence of incipient failures3. Calibration: Periodically determining the value of characteristics of an item by comparison to a standard; it consists of the comparison of two instruments, one of which is certified standard with known accuracy, to detect and adjust any discrepancy in the accuracy of the material/parameter being compared to the established standard valueFleet Maintenance Management22Vehicle Maintenance ProgramMathematical Model for Optimum Preventive Maintenance4. Testing: Periodically testing or checking out to determine serviceability and detect electrical/mechanical-related degradation5. Alignment: Making changes to an items specified variable elements for the purpose of achieving optimum performance6. Adjustment: Periodically adjusting specified variable elements of material for the purpose of achieving the optimum system performance7. Installation: Periodic replacement of limited-life items or the items experiencing time cycle or wear degradation, to maintain the specified system toleranceFleet Maintenance Management23Vehicle Maintenance ProgramFleet Maintenance Management24Vehicle Maintenance ProgamElements of planned maintenance Plan administration

Fleet Maintenance Management25Vehicle Maintenance ProgamElements of planned maintenance Plan administration