Maintenance: The function of production management, that is concerned with day -to-day problem of keeping the physical plant in good working condition.

Maintenance management: Concerned with planning, organising and directing the resources in order to control the availability and performance of the industrial plants to some specified level.

Maintenance means to maintain the facilities in a system upto some desired level of efficiency/some measure of performance i.e to keep assets in a satisfactory condition or to restore these to that condition.

Maintenance management is concerned with planning and controlling Routine , Planned and Preventive maintenance activities of an organization.

Minimizing the loss of productive time. Minimizing the repair time and repair

cost. Minimizing the loss due to production

stoppages. Prolonging the life of capital assets. Minimizing accidents.

Minimizing the total maintenance cost and improving the quality of product and productivity.

Minimize frequency and severity of interruptions.

Maximize production capacity – through high utilization of facility by maximizing useful life of equipment.

Helps in cost control which leads to increased profits.

Facilitates delivery on time leading to customer satisfaction.

Makes the firm competitive. Helps in quality assurance. Helps in employee and customer safety. Facilitates Just-In-Time.

TYPES OF MAINTENANCE

PredictiveMaintenance

RoutineMaintenance

BreakdownMaintenance

PreventiveMaintenance

Planned Maintenance

Running-inMaintenance

Shut downMaintenance

It is an activity which prevents breakdowns, cuts operating costs, and improve output/quality of the product. It is a ‘Stitch in Time’ procedure following the principle that “Prevention is better than cure”. It involves periodic cleaning, servicing, inspection, and replacement of worn parts.

1. Proper design and installation of equipment.

2. Periodic inspection of plant and equipment to prevent breakdowns before they occur.

3. Repetitive servicing, upkeep and overhaul of equipment.

4. Adequate lubrication, cleaning and painting of buildings and equipments.

• Lesser overtime payment to normal and repair workers.

• Fewer large scale repairs and repetitive repairs.

Better spare part control leading to minimum inventory level.

Increased component life cycle. • Energy and time saving. • Reduced equipment or process failure. • Cost savings and reduced capital

investment.

Increases expenditure. Labour intensive. Reduces productivity, increases idle

time and cost of production. Includes performance of unneeded

maintenance. Potential for incidental damage to

components in conducting unneeded maintenance.

Also known as Breakdown maintenance, it implies that repairs are made after the equipment is failed and can not perform its normal function anymore.

• Get equipment back into operation as quickly as possible.

• Control cost of repairs.• Control cost of the idle wages and

material wastage.• Control the investment in

replacement spare parts and machines.

• Control accident cost and tool breakage.

Indifference towards minor faults. Too low or too high voltages. Indifference towards vibration or variant

sound in the system. Use of sub-standard or wrong fuel. Inefficient or neglected cooling system.

No inspection cost. Low cost. Less staff. Production delay.

It involves the identification of future problems before they occur.

Vital Attributes inspection. Use of sensitive instruments. Why Predictive? The cost of Preventive and Breakdown

can be reduced by using predictive maintenance.

It is also known as scheduled maintenance or productive maintenance.

Preparation of facility Register

Maintenance Schedule

History Record

Job SpecificationMonthly Weekly

Maintenance Programme

Maintenance Action Inspection Report

Maintenance Request Suggestions or Feedback

Corrective and ControlAction

Maintenance Programme

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Procedure for Planned Maintenance

It includes activities such as periodic inspection, cleaning, lubrication, and repair of production equipments after their service life. It is of two types:

a) Running Maintenanceb) Shutdown Maintenance

Running maintenance In this type of maintenance, maintenance

work is carried out while the equipment is in the operating condition.

E.g.: Lubricating the bearing while the machine is running.