DAY 1 - AMMJ

52Evolution of MaintenanceTYPES OF MAINTENANCEFACTORSBreakdown /Reactive / Run-tofailuremaintenance(BM)RoutineMaintenance (RM)Scheduledmaintenance (SM)CorrectiveMaintenance (CM)PreventiveMaintenance (PM)Core FocusRepair is undertaken only afterthe failure of theequipment, whichmay be temporaryDone routinely– between every shift,every day or everyweek irrespective ofwear and tear of partsor machinesDone as perschedule – every3 or 6 months oran year based onwear and tear andvary for differentmachinesEliminate / reducerepetitive breakdownsTo prevent andeliminate failureTheory FollowedMachine can runtill failure andmaintenance willbring it back tooriginal conditionRegular maintenancejob at frequentintervals reducesbreakdownA type ofmaintenancebased on pastfailure trend,machine needs andrequirementsCorrecting a failedunit, but ensuring apermanent measurethat breakdown willnot repeat againTaking proactiveactions for correcting aunit before it fails or toprevent failurePerformanceMeasuresFrequency ofbreakdown, Cost ofBreakdownSame as previousand frequency ofmaintenanceNo. of machinesunder schedule, %of backlogFrequency ofbreakdown, No.of failures, No. ofcorrective measuresNo. of m/cs underPM, Reductionin breakdown,Maintenance costreductionTechniquesRepair,Replacement,Lubrication andMinor adjustmentCheck, clean,lubricate, tighten,adjustmentFollows checklistfor inspection,repair, replacementetc.Reconditioning orredesign of machines.Cause and effectanalysisDaily maintenance,Inspection, Makingpreventive repairLossesNo consideration forlossesNo consideration forlossesMeasured in termsof costIn terms of no. of idlehours, Time and costfor maintenanceIn terms of no. of idlehours, Time and costfor maintenanceWhen It IsPerformedIt can start duringthe productionset-up, i.e. duringchangeover fromone product toanotherDependent on no. ofmachines, existingstatus of machines– Done at the startand end or every hour/ shift / day / weekDependent onno. of machines,existing statusof machines– Done as perpredetermined planDependent on no.of machines, type offailure, existing statusof machines, sparesavailability etc.Dependent on no.of machines, type offailure, existing statusof machines, sparesavailability etc.Type of IndustryFollowingData RequiredAll industries exceptindustries havinglarge number ofequipments likeprocess industriesLess compared toother typesSuitable for all type ofcompaniesMore compared toprevious as routinehas to be establishedSuitable for all typeof companiesMore comparedto previous asschedule has to beestablishedStaffing Less More than BM May be same asRMFinancialImplicationLessSlightly higher thanBMSlightly higher thanRMSuitable for all type ofcompaniesMore comparedto previous asreconditioning andredesignMay be same as SMSlightly higher thanSMSuitable for batchproduction, wherevolume is relativelylessMore compared toprevious because ofmonitoringSlightly higherSlightly higher than SMEase and TimeTo ImplementEasy and takes lesstimeEasy and takes lesstimeDepending uponthe equipment,time, cost etc.Depending upon theequipment, failure,cost etc.It needs training,scheduling and hencetakes more timeBreakdown Cost High Slightly lesser Slightly lesser thanRMMaint. Cost Low Slightly higher Slightly higher thanRMSlightly lesser thanSMSlightly higher thanSMSlightly lesser than CMSlightly higher than CM