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PRODUCTION AND

OPERATIONS MANAGEMENT

MAINTENANCE MANAGEMENT

Prof. Arun Mishra

arunjimishra@gmail.com9893686820

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What is Maintenance?

Maintenance: The function of productionmanagement, that is concerned with day -to-day

problem of keeping the physical plant in goodworking condition.

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What is Maintenance Management?

Maintenance management: Concerned with

planning, organising and directing theresources in order to control the availabilityand performance of the industrial plants tosome specified level.

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Scope of Maintenance ManagementPrimary Functions:

Maintenance of existing plant & equipments. Maintenance of existing plant buildings & grounds. Equipment inspection & lubrication. Utilities generation & distribution.

Alterations to existing equipments & building. New installations of equipments & building.Secondary Functions:

Storekeeping Plant protection including fire protection. Waste disposal Salvage Insurance administration Pollution & Noise control.

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Objectives of Maintenance Management1. Minimizing the loss of productive time because of equipment

failure ( i.e., minimizing idle time of equipment due to break down).

2. Minimizing the repair time and repair cost.3. Minimizing the loss due to production stoppages.4. Efficient use of maintenance personnel and equipments.5. To keep all productive assets in good working condition.6. Prolonging the life of capital assets by minimizing the rate of

wear and tear.7. To maximize efficiency and economy in production through

optimum use of facilities.8. To minimize accidents through regular inspection and repair of

safety devices.9. To minimize the total maintenance cost which includes the cost

of repair, cost of preventive maintenance and inventory carryingcosts due to spare parts inventory.

10. To improve the quality of products and to improve productivity.

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Areas of Maintenance

1. Civil Maintenance2. Mechanical Maintenance

3. Electrical Maintenance

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Types of Maintenance

Break-down-Maintenance: Corrective or remedialmaintenance that occurs when equipments or machines fail and must be repaired on an urgent

basis.Preventive maintenance: Maintenance activitiesunder taken before the machines or equipmentsfail. Aims to minimise the possibility of

unanticipated or major break-downs.

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Types of Maintenance

Predictive Maintenance: Modern approach to preventive maintenance using sensitive instrumentsto predict anticipated failure of machines andequipments.

Routine Maintenance: This includes activities suchas periodic inspection, cleaning, lubrication, andrepairs.Planned Maintenance : Maintenance activities that

are carried out according to a predeterminedschedule. Also known as scheduled maintenance or

productive maintenance.

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Maintenance Policy

Maintenance policy is concerned with:

1. extent of maintenance activities and2. size of the maintenance department.

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Economies of Maintenance

At the optimal level of maintenance preventive

maintenance cost equals breakdown maintenancecost.

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Total Productive Maintenance

Total Productive Maintenance: Combines totalquality management concept with strategicview of maintenance from process andequipment design to preventive maintenance.Aims at ZERO Breakdown or Zero DownTime . It is a method designed to eliminate the lossescaused by breakdown of machines &equipments.

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