Assignment Code: MS-57/TMA/JULY/2022

Course Code: MS-57

Assignment Name: Maintenance Management

Year: 2022-2023

Verification Status: Verified by Professor

Attempt all the questions and submit this assignment to the coordinator of your study centre. Last date of submission for July 2022 session is 31st October 2022 and for January 2023 session is 30th April 2023.

Q1) How does Total Maintenance differ from preventive maintenance? Explain with the help of an example from the maintenance department of a nearby plant or any plant that you are more acquainted with.

Ans) Total Maintenance and Preventive Maintenance are two maintenance strategies that are commonly used in industrial plants to ensure the efficient operation of equipment and minimize downtime. While both strategies aim to prevent equipment failure and reduce costs associated with repairs, they differ in their approach and scope.

Preventive Maintenance involves scheduled inspections, cleaning, and repairs to prevent equipment failure. For example, a plant might have a schedule for changing the oil in their machinery every 500 hours of operation, inspecting belts for wear and tear every month, or cleaning filters regularly to prevent clogging. By following this schedule, the plant can identify potential problems before they cause a breakdown, thereby reducing the risk of downtime and minimizing repair costs.

Total Maintenance, on the other hand, is a more comprehensive approach that aims to maximize equipment reliability and availability. It goes beyond just fixing equipment when it breaks or performing regular maintenance tasks, instead focusing on identifying and eliminating the root causes of problems. This involves using advanced techniques such as root cause analysis and reliability-centered maintenance to identify the underlying causes of equipment failure and developing solutions to prevent them from happening again.

To better understand the difference between the two approaches, let us consider an example from a nearby plant that uses both TM and PM strategies.

The plant in question produces automotive parts and relies heavily on a large and complex hydraulic system to operate the machinery. The hydraulic system uses pumps, valves, filters, and piping to control the flow of oil that powers the machines. Any failure or breakdown in this system can lead to significant downtime and production losses.

To prevent such failures, the plant has implemented a PM program that includes regular inspections, cleaning, and repairs of the hydraulic system. For instance, the plant has scheduled monthly inspections of the system's filters to ensure that they are not clogged or worn out. The filters are replaced or cleaned as needed to prevent any damage to the pumps and valves. Additionally, the plant has also scheduled an annual inspection of the entire hydraulic system, where technicians use specialized equipment to test the system's pressure, flow rate, and other parameters. Any potential problems are identified and corrected promptly to prevent equipment failure.

While these PM tasks are essential for preventing equipment failure, they do not address the root causes of problems. To tackle this, the plant has also implemented a TM program that focuses on identifying and eliminating the underlying causes of equipment failure.

The TM program includes several advanced techniques, such as Failure Mode and Effects Analysis (FMEA) and Root Cause Analysis (RCA), to identify and analyse potential equipment failures. For example, the plant has identified a recurring problem with one of the hydraulic pumps that often fails due to overheating. Using RCA, the plant has discovered that the pump's overheating is caused by a restriction in the hydraulic piping that reduces the flow of oil to the pump. By removing the restriction and increasing the flow rate, the plant has been able to prevent pump failures and extend the lifespan of the equipment.

Another example of TM in action is the plant's use of Reliability-Centered Maintenance to optimize the maintenance schedule for critical equipment. RCM involves analysing the criticality of each piece of equipment and determining the optimal maintenance interval based on its expected lifespan and failure modes. By using RCM, the plant has been able to reduce the frequency of maintenance tasks for less critical equipment and increase the frequency for more critical equipment, thereby minimizing the risk of equipment failure and downtime.

Q2) Briefly describe the various applications of the reports from maintenance costing in decision making.

Ans) Maintenance costing reports provide crucial information to decision-makers in an organization, enabling them to make informed decisions on various aspects of maintenance management. The information in these reports helps managers to optimize maintenance processes, reduce downtime, and control costs. In this section, we will discuss various applications of maintenance costing reports in decision-making.

1. Equipment Replacement Decisions: Maintenance costing reports provide information on the total maintenance cost of equipment over time. By analysing this information, decision-makers can determine whether it is more cost-effective to repair or replace equipment. For example, if the maintenance cost of a particular equipment is consistently increasing, decision-makers may consider replacing the equipment instead of continuing to repair it.

2. Maintenance Budgeting: Maintenance costing reports provide data on the actual maintenance costs incurred by the organization. This data can be used to develop more accurate maintenance budgets for future periods. By analysing the cost of maintenance, managers can allocate resources more effectively and efficiently, reducing overall maintenance costs.

3. Asset Management: Maintenance costing reports can provide valuable insights into the performance of assets. By analysing the maintenance costs for each asset, managers can determine which assets are performing well and which ones are not. This information can be used to develop maintenance strategies for each asset, optimizing their performance and extending their lifespan.

4. Maintenance Optimization: Maintenance costing reports can help managers identify areas where maintenance costs can be reduced without compromising performance. By analysing the data, decision-makers can identify maintenance tasks that are not essential and can be eliminated. This can help optimize maintenance schedules, reduce downtime, and improve equipment reliability.

5. Vendor Management: Maintenance costing reports can be used to evaluate the performance of maintenance vendors. By comparing the maintenance costs of different vendors, managers can identify which vendors provide the best value for money. This information can be used to negotiate better contracts with vendors or to switch to more cost-effective vendors.

6. Root Cause Analysis: Maintenance costing reports can provide valuable insights into the root causes of equipment failures. By analysing the data, decision-makers can identify the most common causes of equipment failures and develop strategies to prevent them. This can help reduce downtime and improve overall equipment reliability.

7. Performance Measurement: Maintenance costing reports can be used to measure the performance of maintenance teams. By comparing maintenance costs and downtime across different teams, managers can identify areas where teams are performing well and where they need to improve. This information can be used to develop training programs and performance metrics, improving the overall performance of maintenance teams.

Maintenance costing reports play a critical role in decision-making in maintenance management. They provide valuable insights into the performance of equipment, maintenance processes, and maintenance teams. By analysing this information, decision-makers can develop more effective maintenance strategies, reduce downtime, and control costs. Therefore, it is essential for organizations to develop comprehensive maintenance costing reports and to use them regularly to inform decision-making.

Q3) What are the objectives of the Maintenance Department of your Organization? Evaluate the top management’s strategies, if any, to make a smooth and flawless maintenance function?

Ans) A general overview of the objectives of a maintenance department in an organization, and how top management can implement strategies to ensure a smooth and flawless maintenance function.

Objectives of the Maintenance Department

1. Equipment Reliability and Availability: The primary objective of the maintenance department is to ensure that all equipment and assets are reliable and available when needed. This requires the development and implementation of an effective maintenance strategy that includes preventive maintenance, predictive maintenance, and corrective maintenance.

2. Safety and Compliance: Another key objective of the maintenance department is to ensure that all equipment and assets comply with safety regulations and standards. This requires regular inspections and maintenance to identify and address any safety issues.

3. Cost Control: The maintenance department is responsible for managing maintenance costs and ensuring that the organization is operating within budget. This requires the development and implementation of cost-effective maintenance strategies and the optimization of maintenance schedules.

4. Continuous Improvement: The maintenance department is responsible for continuously improving maintenance processes and practices. This requires ongoing training and development of maintenance personnel, the use of advanced technologies and tools, and the implementation of best practices in maintenance management.

Top Management Strategies

1. Implementation of a Comprehensive Maintenance Management System: To ensure a smooth and flawless maintenance function, top management can implement a comprehensive maintenance management system. This system should include preventive maintenance schedules, a work order management system, equipment tracking, and performance metrics.

2. Investment in Advanced Technologies: Investing in advanced technologies such as predictive maintenance, remote monitoring, and automation can help the maintenance department to optimize maintenance processes and reduce downtime. Top management can allocate funds for the purchase and implementation of these technologies.

3. Encouragement of a Culture of Continuous Improvement: Top management can encourage a culture of continuous improvement in the maintenance department by providing training and development opportunities for maintenance personnel, and by promoting the use of best practices in maintenance management. They can also establish metrics and KPIs to measure the performance of the maintenance department and use them to identify areas for improvement.

4. Collaboration and Communication: To ensure a smooth and flawless maintenance function, top management can foster collaboration and communication between the maintenance department and other departments in the organization. This can help to identify potential issues before they become major problems and ensure that maintenance activities are aligned with the overall objectives of the organization.

The maintenance department plays a critical role in ensuring that equipment and assets are reliable and available when needed. The department's objectives include equipment reliability and availability, safety and compliance, cost control, and continuous improvement. Top management can implement strategies such as implementing a comprehensive maintenance management system, investing in advanced technologies, encouraging a culture of continuous improvement, and fostering collaboration and communication to ensure a smooth and flawless maintenance function.

Q4) What is meant by reliability and explain how it is different from quality? ‘Availability is a more practical and appropriate measure of equipment performance’. Discuss.

Ans) Reliability and quality are two important concepts in the world of manufacturing and engineering. Both these concepts are closely related to each other, but they have different meanings and purposes. In this essay, we will discuss the meaning of reliability and quality and explain the differences between the two. We will also discuss the importance of availability as a measure of equipment performance.

Reliability is the probability that a product or system will perform its intended function without failure, for a specified period and under specified conditions. In other words, reliability is the ability of a product or system to perform as expected for a given period. Reliability is a measure of product performance over time.

Quality, on the other hand, is a measure of how well a product or system meets the requirements or expectations of its users or customers. Quality can be defined as meeting or exceeding customer expectations or requirements. Quality is not just about product performance, but also about other aspects such as safety, usability, and maintainability.

The main difference between reliability and quality is that reliability is a measure of product performance over time, while quality is a measure of how well the product or system meets customer requirements or expectations. Reliability is an internal measure, while quality is an external measure.

Availability, on the other hand, is a measure of how often a product or system is available for use. Availability considers not only the reliability of the equipment but also the time it takes to repair and maintain the equipment. Availability is a practical and appropriate measure of equipment performance because it considers the downtime required for maintenance, repairs, and other activities that may prevent the equipment from being available for use.

Availability is a more practical and appropriate measure of equipment performance than reliability because it considers the downtime required for maintenance, repairs, and other activities that may prevent the equipment from being available for use. A highly reliable piece of equipment that is down for extended periods due to maintenance and repair is not very useful to the organization, and it may not meet the availability requirements of the operation.

The importance of availability as a measure of equipment performance can be further highlighted by the concept of total productive maintenance. TPM is a maintenance strategy that aims to maximize the availability of equipment by involving all employees in the maintenance process. TPM focuses on preventive maintenance, which aims to prevent breakdowns and reduce downtime.

TPM aims to improve the availability of equipment by involving all employees in the maintenance process. This involves training employees to identify and report equipment problems, conducting regular inspections and maintenance, and making improvements to equipment design and operation to improve reliability and maintainability. TPM also aims to improve equipment performance by reducing setup times, reducing cycle times, and improving product quality.

Reliability and quality are two important concepts in the world of manufacturing and engineering. While they are related to each other, they have different meanings and purposes. Reliability is a measure of product performance over time, while quality is a measure of how well the product or system meets customer requirements or expectations. Availability is a practical and appropriate measure of equipment performance because it considers the downtime required for maintenance, repairs, and other activities that may prevent the equipment from being available for use. Availability is important because it ensures that equipment is available when it is needed, which is essential for efficient and effective operations.

Q5) Distinguish productive maintenance from preventive maintenance.

Ans) Productive maintenance and preventive maintenance are two maintenance strategies commonly used in manufacturing and engineering industries. While both strategies aim to reduce equipment downtime, there are some key differences between them.

Preventive maintenance is a maintenance strategy that involves regularly scheduled maintenance activities to prevent equipment breakdowns and reduce downtime. Preventive maintenance is typically performed based on a predetermined schedule, which may be based on time or usage. In preventive maintenance, maintenance activities such as inspections, lubrication, and replacement of worn parts are performed before they fail or cause downtime.

On the other hand, productive maintenance is a maintenance strategy that aims to improve equipment reliability and reduce downtime by involving all employees in the maintenance process. Productive maintenance focuses on improving the overall effectiveness of the production process by eliminating equipment-related losses. Productive maintenance aims to reduce the frequency and duration of equipment breakdowns and repairs.

One of the key differences between productive maintenance and preventive maintenance is the scope of the maintenance activities. Preventive maintenance is typically limited to routine maintenance activities, such as inspections, lubrication, and replacement of worn parts. Productive maintenance, on the other hand, includes a broader range of activities, such as improving maintenance procedures, training employees, and implementing equipment upgrades.

Another key difference between the two strategies is the frequency of maintenance activities. Preventive maintenance is typically performed on a regular schedule, regardless of the condition of the equipment. Productive maintenance, on the other hand, is based on the actual condition of the equipment and involves maintenance activities only when needed.

In productive maintenance, there are three main types of activities: planned maintenance, autonomous maintenance, and continuous improvement. Planned maintenance involves identifying and addressing equipment problems before they cause downtime. Autonomous maintenance involves training operators to perform routine maintenance tasks such as cleaning, inspection, and lubrication. Continuous improvement involves identifying and eliminating the root causes of equipment-related losses, such as equipment design, operating procedures, and maintenance practices.

In contrast, preventive maintenance does not typically involve employees in the maintenance process, and maintenance activities are performed by a dedicated maintenance team. Preventive maintenance typically involves only routine maintenance activities and does not focus on improving the overall effectiveness of the production process.

Another difference between the two strategies is the cost involved. Preventive maintenance is typically less expensive than productive maintenance, as it involves only routine maintenance activities. In contrast, productive maintenance involves more activities and may require more investment in equipment upgrades, employee training, and process improvements.

While both productive maintenance and preventive maintenance aim to reduce equipment downtime, they differ in their approach. Preventive maintenance involves regularly scheduled maintenance activities based on time or usage and is typically performed by a dedicated maintenance team. Productive maintenance involves all employees in the maintenance process and focuses on improving the overall effectiveness of the production process by eliminating equipment-related losses. Ultimately, the choice between productive maintenance and preventive maintenance depends on the specific needs and goals of the organization.