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47 views9 pagesUnit 5 (Iim)
5th unit complete
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akashCopyright
© © All Rights Reserved
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B
Plant Maintenaneg
13.1. PLANT "
Aplant isa place, where men, materials, money, equipment,
for manufacturing products.
13.2, MAINTENANCE .
Today, in modern industry, equipment and machinery are a vevy sae ae Of the tora)
productive effort than was the case years ago. Moreover, with the eloped of spec pure
‘and sophisticated machines, equipment and machinery cost a lot more m es anes their aig
or downtime becomes much more expensive. For this reason, it is vitally important that the
plant machinery should be properly maintained.
13.3. OBJECTIVES OF PLANT MAINTENANCE
@ The objective of plant maintenance is to achieve minimum breakdown and to keep the plant in
good working condition at the lowest possible cost. ; : :
(i) Machines and other facilities should be kept in such a condition which permits them tobe useq
at their optimum (profit making) capacity without any interruption or hindrance,
(iii) Maintenance division of the factory ensures the availability of the machines, buildings and
services required by other sections of the factory for the performance of their functions at optimum
return on investment whether this investment be in material, machinery or personnel.
13.4. IMPORTANCE OF MAINTENANCE.
(@® The importance of plant maintenance varies with the type of plant and its production.
(@ Equipment breakdown leads to an inevitable loss of production.
machinery, tate Brought topes
~ Ifa piece of equipment goes out of order in a flow production factory, the whole line will soon
come to a halt, Other production lines may also stop unless the initial fault is cleared,
~ This results in an immediate loss in productivity and a diminution of several thousand
Tupees per hour of output.
(ii) An unproperly maintained or neglected plant will sooner or later require expensive and
i repairs, because with the passage of timeall machines or other facilites (such as transporiation
Facilities), buildings, et, wear out and need to be maintained to function propery.
@) Plant maintenance plays a prominent role in. production martagement because plant
breakdown creates problems such as =a
— Loss in production time.
~—_ Rescheduling of production.
7 Spoilt materials (because sudden stoppage of process damages in-process materials),
> Failure to recover overheads (because of loss in production hours).INDUSTRIAL ENGINEERING AND MANAGRag
B-5 0 ate SEMEN
(e) Nature of industry, ie, whether itis primarily 20 electrical, electronics, chemical oy «
mechanical industry.
' ability 0 :
(f) State of training and relia ae ian
(6) Inestablishing a maintenance organisation, it 18 68 sential tad i Pe.
(a) the plant is to be maintained at a level consistent with low cost and high productivity ;
(©) supervisors should be appointed according to the duties and responsibilities involved ; ang
(c) modern age indicates greater need of newer engineering techniques and skills.
13.7. TYPES OF MAINTENANCE
‘Maintenance may be classified into followin,
(a) Corrective or breakdown maintenance,
(b) Scheduled maintenance,
(©) Preventive maintenance, and
(@ Predictive maintenance.
13.8. CORRECTIVE OR BREAKDOWN MAINTENANCE,
— Corrective or breakdown maintenance implies that repairs are made after the equipment is out
of order and it cannot perform its normal function any longer, e.g, an electri¢ motor will not
start, a belt is broken, ete.
— Under such conditions, production department calls on the maintenance department to rectify
the defect. The maintenance department checks into the difficulty and makes the necessary
repairs,
— After removing the fault, maintenance engineers do not attend the equipment again until
another failure or breakdown occurs.
f work force.
g categories :
= This ype of maintenance may be quite justified in small factories which :
(are indifferent to the benefits of scheduling ;
(i) do not feel a financial justification for scheduling techniques ; and
(ifi) get seldom (temporary or permanent) demand in excess of normal operating capacity.
= In many factories make-and-mend is the rule rather than the exception.
— Breakdown maintenance practice is economical for those (non-critical) equipments whose
down-time and repair costs are less this way than with any other type of maintenance.
~ Breakdown type of maintenance involves little administrative work, few records anda compara-
tive small staff.
‘There is no planned interference with production programmes.
— Typical Causes of Equipment Breakdown
(i) Failure to replace worn out parts,
(i) Lack of lubrication,
(ii) Neglected cooling system.
(iv) Indifference towards minor faults,
(») External factors (such as to0 low or too high line voltage, wrong fuel, etc)pANTMAINTENANCE
(vi) Indifference towards ~equi
cninery, equipment getting too much heed a
rations, unusua oe
] selg, sUalsoundscomingoutotthe rotating ma:
= Disadvantages of Breakdown Maintenance
(© Breakdowns generally occuratinopportunate
and excessive delays in production, ‘etimes. This leads 10 poor
(i) Reduction of output,
(iii) Faster plant deterioration
(iv) Increased chances of accidents and less safety 0 bo)
s 8S sa
twee suite fety (0 both workers and machines,
(vi) Direct toss of profit,
(vif) Breakdown maintenance practice can;
regulated by statutory provisions, for example cran;
139, SCHEDULED MAINTENANCE
Wurtied maintenance
Inot be employed for those plant items which are
es, lifts, hoists and pressure vessels,
Scheduled maintenance isa stich-in-time procedure aimed at avoiding breakdowns,
— Breakdowns can be dangerous to life and as far as possible should be minimized.
— Scheduled maintenance practice incor
haul of certain equipments which if n
Inspection, lubrication, servicing,
schedule.
porates (in it), inspection, lubrication, rey
replected can result in breakdown,
€tc., of these equipments are included in the predetermined
~ Scheduled maintenance practice is generally followed for overhauling of machines, cleaning of
water and other tanks, white-washing of buildings, etc,
1310 PREVENTIVE MAINTENANCE,
Introduction
= Asystem of scheduled, planned or preventive maintenance tries to minimize the problems of
breakdown maintenance.
= Itisastich-in-time procedure,
— It locates weak spots (such as bearing surfaces, parts under excessive vibrations, etc.) in all
equipments, provides them regular inspection and minor repairs thereby reducing the danger of
unanticipated breakdown. The underlying principle of preventivemaintenance is that prevention
is better than cure,
Preventive Maintenance (or PM) Involves
(a) Periodic inspection of equipment and machinery to uncover conditions that lead to production
breakdown and harmful depreciation.
() Upkeep of plant equipment to correct such conditions while they are still n'a minor stage,
— Preventive maintenance is practised to some extent in about 75% of all manufacturing compa-
nies, but every preventive sPrintenance programme is tailored as per the requirements of each
company,
— The key to all good preventive maintenance programmes,
table statistical techniques in order to find how often to inspect.
however, is inspection,
~ Help can be taken of su
_ ntl,
INDUSTRIAL ENGINEERING AND MaNaggy i
7 ” ‘“
ives of PM i ‘ a
Or: is ¥ ve the possibility of unanticipated production interruption oF major breakaym py ‘ Pe £
i) To minimiz ity of un ee down |
locating or uncovering any condition which pro aid echo a oe
ji) To make plant equipment and machinery ala pend rent
tity Tomaineinthevateeofequipmentand machinery by peiodiisPectOns reais, overpay, Ba
etc. :
Gv) To maintain the optimum productive efficiency of the plant emionet and machinery, Ww ¥
(¥) To maintain the operational accuracy of the plant equipment, r
(Vi) To reduce the work content of maintenance jobs.
(ii) To achieve maximum production at minimum repair cost. ‘
(vii) To ensure safety of life and limbs of the workmen.
Elements (or Procedure) of Preventive Maintenance " ;
( There is no ready-made, on-the-shelf, preventive maintenance programme for any industry. j,
‘must be tailor-made-measured and cut to fit the requirements of individual industry or plant ; this jg
because all industries differ in size, age, location, machinery, resources, layout, and construction,
(i) A wellconceived preventive maintenance programme contains the following elemeny,
features or steps.
1. Who should do PM ?
Preventive maintenance may be taken care by
@ Production department,
(©) Maintenance department.
© A separate division of inspectors, crafts and supervisors.
— Thechoice depends upon, again, the conditions (such as size, age, location, machinery, ete) of
the plant,
~ However, a perfect coordination between production department and PM personnel is highly
