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12/18/2012

MBA I yr E- Batch

Breakdown Maintenance
INTRODUCTION

Maintaining the production capability of an organization is an important function in any production system. Maintenance encompasses all those activities that relate to keeping facilities and equipment in good working order and making necessary repairs when breakdowns occur, so that the system can perform as intended. Maintenance activities are often organized into two categories: (1) buildings and grounds, and (2) equipment maintenance. Buildings and grounds is responsible for the appearance and functioning of buildings, roads, parking lots, lawns, fences, and the like. Equipment maintenance is responsible for maintaining machinery and equipment in good working condition and making all necessary repairs. The goal of maintenance is to keep the production system in good working order at minimum cost. There are several reasons for wanting to keep equipment and facilities in good operating condition, such as to: 1. avoid production disruptions 2. not add to production costs 3. maintain high quality 4. avoid missed delivery dates When breakdowns occur, there are a number of adverse consequences: 1. Production capacity is reduced, and orders are delayed. 2. There is no production, but overhead continues, increasing the cost per unit. 3. There are quality issues; product may be damaged. 4. There are safety issues; employees or customers may be injured. Decision makers have two basic options with respect to maintenance. One option is reactive: it is to deal with breakdowns or other problems when they occur. This is referred to as breakdown maintenance. The other option is proactive: it is to reduce breakdowns

through a program of lubrication, adjustment, cleaning, inspection, and replacement of worn parts. This is referred to as preventive maintenance. The definition of Breakdown Maintenance is, let the machine run its course to the point of not being able to function properly and then fix it. Opposed to preventive maintenance in which a maintenance schedule is assigned to a machine before a breakdown ever occurs, preventing future delays in production. There is then also, predictive maintenance in which you base the maintenance schedule on the history of past failures, preventing these failures or breakdowns just before they are predicted to occur.

Types of Maintenance:

Breakdown Maintenance You wait until the machine completely fails, then you repair

it to working order. Usually assigned to machines with backups in place, or machines which are of low importance to production.

Preventive Maintenance You maintain the machine, while still in operation to prolong

or prevent the machines failure. This should be applied to machines of importance and high value when compared to production.

Predictive Maintenance You predict when the machine may require maintenance

based on analysing past history, and apply maintenance just before the machine has failed in the past, extending its service life. Often applied in conjunction with Preventative Maintenance.

Periodic Maintenance - A set schedule of maintenance routines assigned to prolong the

life of the machine.

Breakdown maintenance is usually applied on machines which are not the backbone of the project. For example, in a factory, if a machine is of little importance to whether production carries on, or there are backup procedures in place for said machine, it may be cheaper and more efficient for the company to send a maintenance worker to the machine when it actually breaks, as opposed to assigning a work order periodically on the machine as

it is still performing up to par. This cuts back in labour hours for the company, as well as cost of operation. You yourself probably perform breakdown maintenance on a routine basis in many aspects of your life, disregarding, preventive, predictive, and periodic maintenance when they could have prevented a problem, but just were not worth the time.

Common Place Breakdown Maintenance:

Your cars battery; you wait until it actually has an issue, perhaps not having enough power to turn your cars engine over. There are back-up procedures in place; you can simply get a boost and drive that same care to the hardware store where you can purchase a new battery. This is breakdown maintenance.

The replaceable blade on your razor. You dont use preventative maintenance on it periodically by sharpening it and trying to get the longest life out of it, when it is so easily replaced. You simply wait until it seizes to function properly, and replace it with a new disposable blade. This is break down maintenance.

Examples of where breakdown maintenance is avoided:

An air plane - Preventive, and periodic maintenance is applied throughout, never in an airplane do they allow a system to simply breakdown before they decide to replace, or maintain it.

Vehicle Tires Usually, in the name of safety, a person applies periodic maintenance to such an object. You do not want to apply breakdown maintenance, as driving until your tire blows, and fails could put your life in jeopardy. It is much more appropriate to assess the tire periodically for wear, and replace it when needed, before the point of breaking down.

Maintenance schedule assignment

An excellent way to assess which type of maintenance, whether it is breakdown maintenance or another, that you should assign to a machine is to refer to the owners manual. Within, should usually be the type of maintenance you should apply, and the steps as well as tools you will need to complete the task. Other factors also weigh in though, how

important to the operation is this machine, or part? If it breaks down, what are the consequences? Is it easy and affordable to constantly maintain, or more worth it to replace when it stops working correctly?

Maintenance Strategies or Options

A maintenance strategy or option means a scheme for maintenance, i.e. an elaborate and systematic plan of maintenance action. Following are the maintenance strategies [1] that are commonly applied in the plants.

Breakdown Maintenance or Operate to Failure or Unplanned Maintenance Preventive or Scheduled Maintenance Predictive or Condition Based Maintenance Opportunity Maintenance Design out Maintenance

The equipment under breakdown maintenance is allowed to run until it breaks down and then repairing it and putting back to operation. This strategy is suitable for equipments that are not critical and have spare capacity or redundancy available. In preventive or scheduled Maintenance, maintenance actions such as inspection, lubrication, cleaning, adjustment and replacement are undertaken at fixed intervals of numbers of hours or Kilometers. An effective PM program does help in avoidance of accidents. Condition monitoring (CM) detects and diagnoses faults and it helps in planned maintenance based on equipment condition. This condition based maintenance strategy or predictive maintenance is preferred for critical systems and for such systems breakdown maintenance is to be avoided. A number of CM techniques such as vibration, temperature, oil analysis, etc. have been developed, which guide the users in planned maintenance [2]. In opportunity maintenance, timing of maintenance is determined by the procedure adopted for some other item in the same unit or plant. In design out maintenance, the aim is to minimize the effect of failures and in fact eliminates the cause of maintenance. Although it is an engineering design problem, yet it is often a responsibility of maintenance department. This is opted for items of high maintenance cost that are due to poor maintenance, poor design or poor design outside design specifications. It may be mentioned that a best maintenance

strategy for each item should be selected by considering its maintenance characteristics, cost and safety. In addition to the above, new strategies concepts such as Proactive Maintenance, Reliability Centred Maintenance (RCM), Total Productive Maintenance (TPM), etc. have recently been evolved to look it from different perspectives and this has helped in developing effective maintenance. In proactive maintenance, the aim is identify what can go wrong, i.e. by monitoring of parameters that can cause failures. In RCM, the type of maintenance is chosen with reliability of the system in consideration, i.e. system functions, failures relating to those functions and effects of the dominant functional system failures. This strategy in the beginning was applied to critical systems such as aircrafts, nuclear and space applications. At present, this is being extended to critical systems in the plant. TPM, a Japanese concept, involves total participation of all concerned. The aim is to have overall effectiveness of the equipment with participation of all concerned using productive maintenance system.

Functions of a maintenance department

Following are the major functions of a maintenance department [3-4]: Maintenance of installed equipment and facilities Installations of new equipment and facilities PM tasks Inspection and lubrication of existing equipment CM tasks monitoring of faults and failures using appropriate techniques Modifications of already installed equipment and facilities Management of inventory Supervision of manpower Keeping records

Maintenance Organisation
It concerns in achieving an optimum balance between plant availability and maintenance resource utilization. The two organization structures that are common are: Centralized and Decentralized. A decentralized structure would probably experience a lower utilization than

centralized one but would be able to respond quickly to breakdowns and would achieve higher plant availability. In practice, one may have a mix of these two. A maintenance organization can be considered as being made up three necessary and interdependent components. Resources: men, spares and tools Administration: a hierarchy of authority and responsibility for deciding what, when and how work should be carried out. Work Planning and Control System: a mechanism for planning and scheduling the work and feeding back the information that is needed for correctly directing the maintenance effort towards defined objective. It may be mentioned that maintenance / production system is a continuously evolving organism in which the maintenance organization will need continuous modifications in response to changing requirements. Moreover, it is required to match the resources to workload. Maintenance activities be it preventive or condition monitoring, involve use of resources- men and materials including documents. This requires coordination amongst the involved personnel so that these are timely undertaken. Work planning and control system under maintenance management in the plant ensures this and provides planning and control of activities associated with maintenance. This means application of general management principles of planning, organizing, directing and controlling to the maintenance functions, e.g. to the establishment of procedures for development of maintenance strategy and to models for describing the flow of work through maintenance work planning department. Control system controls the maintenance cost and plant condition.

Elements of effective maintenance

An effective maintenance system includes the following elements [3-4]:

Maintenance Policy Control of materials Preventive Maintenance Condition Monitoring Work Order Job planning Priority and backlog control Data recording system Performance measurement measures or indices

Maintenance performance for a plant or an organization can be accessed through analysis of Reliability, Availability and Maintainability (RAM) plant data. Relevant parameters, measures or indices for specific plants can be identified [5]. The performance over a period of time will show if it is improving, going down or being sustained. This will also help in knowing how well the objectives are being met. In addition, it will guide the areas which are strong and which need to be strengthened. Use of computers and dedicated software will certainly help in implementing this and the maintenance management system in general.

Major approaches used to deal with breakdowns

Among the major approaches used to deal with breakdowns are the following: 1. Standby or backup equipment that can be quickly pressed into service. 2. Inventories of spare parts that can be installed as needed, thereby avoiding lead times involved in ordering parts, and buffer inventories of work-in-process, so that other equipment will be less likely to be affected by short-term downtime of a particular piece of equipment. 3. Operators who are able to deal with emergencies (e.g., know how to lock up equipment), and perform at least minor repairs on their equipment. 4. Repair people who are well trained and readily available to diagnose and correct problems with equipment.

The degree to which an organization pursues any or all of these approaches depends on how important a particular piece of equipment is to the overall production system. At one extreme is equipment that is the focal point of a system (e.g., printing presses for a newspaper, or vital operating parts of a car, such as brakes, steering, transmission, ignition, and engine). At the other extreme is equipment that is seldom used because it does not perform an important function in the system, and equipment for which substitutes are readily available. The implication is clear: breakdown maintenance is most effective when it takes into account the degree of importance a piece of equipment has in the production system, and the ability of the system to do without it for a period of time. The Pareto phenomenon exists in such situations: a relatively few pieces of equipment will be extremely important to the functioning of the system, thereby justifying considerable effort and/or expense; some will require moderate effort or expense; and many will justify little effort or expense.