engg zc242-l1

BITS Pilani Pilani Campus

ENGG ZC242 Maintenance & Safety

Girish Kant Department of Mechanical Engineering

ENGG ZC242, Maintenance and Safety,

29/07/2014, Lecture-1 1


Introduction to Maintenance Systems

Chapter – 1, Lecture-1

BITS Pilani, Pilani Campus

Course Handout

Definitions of Maintenance

History of Maintenance

Maintenance Objectives/Scope and Benefits/Policies

Learning Objectives


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Objectives, Functions, and Types of maintenance

Defect due to wear, lubrication, maintenance of different

equipments and their elements

Management of maintenance function, spares planning,

overhauling and TPM

Safety and safety management, environmental safety,

chemical safety, occupational health management,

control of major industrial hazards, managing

emergencies, employee participation in safety and HRD

for maintenance and safety.

Course Description


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The objective of the course is to make students

understand the concepts of maintenance and safety

and their importance in industry.

The course deals with the planning and control of

various maintenance engineering.

The learning of the basic and recent trends in

maintenance engineering will help the students in their

professional life. The safety portion the course will

enable the students to deal with effectively the various

types of hazard in industry.

Scope and Objectives


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K. Venkataraman, Maintenance Engineering and

Management, Prentice Hall of India, 2007.

Prescribed Text Book


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Mishra R.C. & K. Pathak, Maintenance Engineering and

Management, Prentice-Hall of India., 2002

Sushil Kumar Srivastava, Industrial Maintenance

Management, S. Chand & Company, 2002.

Krishnan N.V., Safety Management in Industry, Jaico

Publishing House, 1993.

L M Deshmukh, Industrial Safety Management, TMH,

2006.

Reference Books


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Maintenance Management: Its Auditing and

Benchmarking: In Search of Maintenance Management

Excellence by Anthony Kelly , Industrial Press © 2006

(336 pages) Citation

Total Productive Maintenance by Terry Wireman ,

Industrial Press © 2004 (204 pages)

Reference 24×7 e-Books www.books24x7.com


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Plan of Study - I


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Week No. Chapter Name Objective/Topic Reference to Text Books

1 Introduction to Maintenance Systems Maintenance as Business Proposition, Maintenance Philosophy, Types of Maintenance systems

T1-Chapter 1

2 Maintainability Measure of maintainability, Methods of Evaluation of Maintainability, Design for Maintainability

T1-Chapter 2

3-4 Condition-Based Maintenance (CBM) Improvement effectiveness thru’ CBM, various CBM techniques

T1-Chapter 3

5-6 Reliability – Centred Maintenance (RCM) Reliability being active and standby, FMECA, RCFA, Criticality analysis

T1-Chapter 4

7 Asset and Spare Parts Management Asset management function, EOQ, 2-Bin system of material procurement, computing

T1-Chapter 5

8 Maintenance Lubricants and Their Applications

Appendix – I

Key Definitions in Lubrication Appendix – II

9 Review Session Syllabus for Mid- Semester Test (Closed Book): Topics in Week No. 1 to 9


Plan of Study - II


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Week No. Chapter Name Objective/Topic Reference to Text Books

10-11 Safety Engineering and Fault Tree Analysis Hazard analysis, , General rules in fire hazard and safety, Faulty tree analysis

T1-Chapter 6

12 Total Productive Maintenance Methodology, Origin, Implementation, Lean Maintenance, Training and monitoring

T1-Chapter 7

13 Maintenance Planning and Scheduling Maintenance planning, Shutdown planning and execution

T1-Chapter 8

14 Computer Applications in Maintenance Management

CMMS, data acquisition, software failure, software security

T1-Chapter 9

15 Statistical Distribution in Preventive Maintenance

Types of distributions, Normal distribution, Gamma distribution, Binomial distribution etc.

T1-Chapter 10

16 Maintenance Integration Steps of integration, future trends T1-Chapter 11

17 Maintenance Effectiveness Elements of effectiveness, Presentation of data, OEE, Agility etc.

T1-Chapter 12

18 Review Session Syllabus for Comprehensive Exam (Open Book): All topics given in plan of study (I & II)


Evaluation Scheme

EC

No.

Evaluation

Component &

Type of Examination

Duration Weightage Day, Date,

Session,Time

EC-1 Quiz -- 15% --

EC-2 Mid-Semester Test

(Closed Book)*

2 Hours 35% Sunday,

14/09/2014 (AN)

2 PM – 4 PM

EC-3 Comprehensive

Exam

(Open Book)*

3 Hours 50% Sunday,

09/11/2014 (AN)

2 PM – 5 PM


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Evaluation Scheme (EC-1 Quiz)

EC-1 No. Syllabus Weightage To be

administered

online during

Quiz – 1 Chapter 1-3 5% August 16 to

January 26, 2014

Quiz – 2 Chapter 4-6,

Appendix I & II

5%

September 16 to

September 26,

2014

Quiz – 3 Chapter 7-12 5%

October 13 to

October 23, 2014


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• Closed Book Test: No reference material of any kind will

be permitted inside the exam hall.

• Open Book Exam: Use of any printed / written reference

material (books and notebooks) will be permitted inside

the exam hall. Loose sheets of paper will not be

permitted. Computers of any kind will not be allowed

inside the exam hall. Use of calculators will be allowed in

all exams. No exchange of any material will be allowed.

Nature of Exam


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Note

It shall be the responsibility of the individual student to be regular in

maintaining the self study schedule as given in the course handout, attend

the online/on demand lectures as per details that would be put up in the

BITS LMS Taxila website www.taxila.bits-pilani.ac.in and take all the

prescribed components of the evaluation such as Assignment (Course Page

on LMS Taxila), Mid Semester Test and Comprehensive Examination

according to the Evaluation Scheme given in the respective Course Handout.

If the student is unable to appear for the Regular Test/Examination due to

genuine exigencies, the student must refer to the procedure for applying for

Make-up Test/Examination, which will be available through the Important

Information link on the BITS WILP website on the date of the Regular

Test/Examination. The Make-up Tests/Exams will be conducted only at

selected exam centres on the dates to be announced later.


Introduction to Maintenance Systems

Chapter - 1


Maintenance refers to all the activities which assist in

keeping plant & equipment in good condition.

Any activity such as tests, measurements,

replacements, adjustments and repair, intended to

restore or retain a functional unit in a specified state in

which the unit can perform its required functions.

What is Maintenance?


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Maintenance is not merely preventive maintenance,

although this aspect is an important ingredient.

Maintenance is not lubrication, although lubrication is

one of its primary functions.

Maintenance simply a frenetic rush to repair a broken

machine part or building segment, although this is more

often than not the dominant maintenance activity.

Maintenance Definitions


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Maintenance is a science since its execution relies,

sooner or later, on most or all of the sciences.

It is an art because seemingly identical problems

regularly demand and receive varying approaches and

actions and because some managers, foremen, and

mechanics display greater aptitude for it than others

show or even attain.

It is above all a philosophy because it is a discipline

that can be applied depending upon a wide range of

variables that frequently transcend more immediate and

obvious solutions.



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Maintenance is a philosophy because it must be

carefully fitted to the operation or organization. it serves

as a fine suit of clothes is fitted to its wearer because

the way it is viewed by its executors will shape its

effectiveness.



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• Maintenance can be defined as a set of activities that

ensure any physical asset to continue to fulfill its

intended functions to the standard of performance

desired by the user.

• Repair & Maintenance

Is fixing or setting things all right for any sort of

mechanical or electrical devices if the same gets out of

the order or broken down as well as performing the

routine actions which keep the device in working order or

prevent trouble from arising.

Maintenance Definition


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• Pre world war II (pre 1945)

• 1945-1970

• 1970 onwards

History of Maintenance


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Maintenance Objectives


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Operational – Maximum operating efficiency of plant

– Maximum availability of plant

– High Quality performance

– Safety

– To maintain a plant clean & good appearance

– To extend Plant life to the last limit

– To reduce environmental impact due to machinery etc

– To provide service that will avert all breakdowns at all times at any cost.

Cost – Minimize maintenance expenditure and maximize profits

– To provide activities with in the limits of budgetary control


Maintenance Benefits


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Financial

Organizational

Technical

Human

Customer relations


Financial Benefits


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Extended Plant Life

Uninterrupted production

Improved quality of production

Reduced production delays

Reduced cost of repairs


Organizational Benefits


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Co-ordination between production and maintenance

Man power planning

Planning of deliveries


Technical Benefits


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Improved equipment suitability

Build up of technical data

Improved maintenance schedules

Improved plant condition


Human considerations Benefits


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Increased Safety

Improved House keeping

Less friction between relationships


Customer relationship Benefits


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Reliable delivery calls

“Show case” house keeping


Maintenance Policy


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Scope and limits of maintenance

Type and level of service expected

Responsibilities to management

Personal Practices

Trade union contracts

Budget and financial controls


Primary Functions – Maintenance of existing plant equipment

– Maintenance of existing plant buildings and grounds

– Equipment inspection and lubrication

– Utilities generation and distribution

– Alterations and new installations

Secondary Functions – Storekeeping

– Plant protection

– Waste disposal

– Salvage

– Insurance

– Other services

Maintenance Functions


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• Repair, lubrication, overhaul, inspection, replacement of

parts

• Training of the maintenance staff

• Training of the production staff

• Testing parts for suitability

• Planning of servicing schedules

• Improvement and modifications of plant

• Production of spare parts

What does maintenance really do?


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Protecting the buildings, structures and plants.

Increase equipment availability & reducing

downtime.

Controlling & directing labour forces.

Economy in maintenance department.

Maximum utilization of available resources.

Preparing maintenance budgets.

Emphasis on waste recovery.

Improving technical communication.

Preventing waste of tools, spare and other materials.

Maintenance System of Today

32 ENGG ZC242, Maintenance and Safety,

29/07/2014, Lecture-1


For achieving these objectives various

control functions & actions are to be taken

which would be discussed in subsequent

chapters.

33 ENGG ZC242, Maintenance and Safety,

29/07/2014, Lecture-1


Comment on the following statements

Maintenance is a necessary evil

Maintenance is a bottomless pit for expenses

Maintenance is known as Time lag effect

Maintenance is a composite function

Lesser the demand better the service

What type of conditions prevailing with in the company that

affect the demand upon the maintenance department?

Summary


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Thanks


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engg zc242-l1

Documents

maintenance philosophy

concepts of maintenance

maintenance systems

types of maintenance

industrial safety management

pilani campus objectives

chemical safety

environmental safety