Industrial Maintenance Meeting by Slidesgo.pptx

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1. The Impact and Evolution of Maintenance Here is where your presentation begins

2. Objectives To quantify the operational and financial impact of different maintenance strategies To Establish a Framework for a Maintenance Strategy To Introduce Key Maintenance Metrics (MTBF, MTTR, MTTF, OEE) To Reinforce the Importance of Maintenance To increase functional reliability of production facilities

3. Introduction Plant maintenance is an important service function of an efficient production system. It helps in maintaining and increasing the operational efficiency of plant facilities. Maintenance is the procedure of finding the faults in any equipment / Machine and also removal of fault. It may be before the breakdown or after the breakdown. Plant maintenance usually refers to the methods, strategies, and practices used to keep an industrial factory running efficiently. This can include anything from regular checks of equipment to make sure they are functioning properly. a The general aim of plant maintenance is to create productive working environment that is also safe for workers.

4. MAINTENANCE Industrial and process plants typically utilize two types of maintenance management: (1) run-to-failure , or (2) preventive maintenance . Run-to-failure maintenance is a reactive approach where equipment is only fixed after it breaks. While this "if it ain't broke, don't fix it" logic seems simple, it is actually the most expensive maintenance method. A true run-to-failure approach is rare, as most plants still do basic tasks like lubrication. However, it avoids major repairs until a failure occurs. This leads to high costs from: Large spare parts inventories Overtime labor Significant machine downtime and lost production Because failures are unexpected, repairs are rushed and inefficient. A repair done in a reactive mode typically costs three times more than the same repair would if it were planned and scheduled in advance.

5. Preventive maintenance It is based upon the principle that 'prevention is better than cure’. Preventive maintenance schedules repairs and overhauls based on time or operating hours, using historical data like Mean Time Between Failures (MTBF). The goal is to service equipment, like rebuilding a pump every 17 months, before it fails. It is a set of activities that are performed on plant equipment, machinery, and systems before the occurrence of a failure in order to protect them and to prevent or eliminate any degradation in their operating conditions. Or the maintenance carried out at predetermined intervals or according to prescribed criteria and intended to reduce the probability of failure or the degradation of the functioning and the effects limited. It has three types Running maintenance Scheduled maintenance Shut down maintenance

6. predictive maintenance Like preventive maintenance, predictive maintenance has many definitions. To some, predictive maintenance is monitoring the vibration of rotating machinery in an attempt to detect incipient problems and to prevent catastrophic failure . To others, it is monitoring the infrared image of electrical switchgears, motors, and other electrical equipment to detect developing problems As the names implies it involves the prediction of the failure before it occurs, identifying the root cause for those failures symptoms and eliminating those causes before they result in extensive damage of the equipment. Type of maintenance performed continuously or at intervals according to the requirements to diagnose and monitor a condition or system. Also called condition based maintenance.

7. Procedure of Preventive maintenance

8. maintenance strategy A maintenance strategy defines the rules for the sequence of planned maintenance work. It contains general scheduling information, and can therefore be assigned to as many maintenance task lists (PM task lists) and maintenance plans as required. A maintenance strategy contains maintenance packages in which the following information is defined: The cycle in which the individual work should be performed (for example, every two months, every 3,106.86 miles, every 500 operating hours) Other data which affects scheduling A maintenance strategy consists of: Strategy header: Name of the strategy, Scheduling parameters: Contain the scheduling data for the respective maintenance strategy, which influence the scheduling of maintenance plans. Scheduling indicators Maintenance packages

9. What is Reliability? Reliability can be defined as the probability that a product, system or service will perform its intended function adequately for a specified period of time, without failure. Or in other hand, we can say ”its the probability that an item can perform its intended function for a specified interval under stated conditions." . Reliability is the ability of a vehicle to run consistently with few surprises.

10. Cont … The most important components of this definition must be clearly understood to fully know how reliability in a product or service is established: Probability:  the likelihood of mission success Intended function:  for example, to light, cut, rotate, or heat Satisfactory:  perform according to a specification, with an acceptable degree of compliance Specific period of time:  minutes, days, months, or number of cycles Specified conditions:  for example, temperature, speed, or pressure Stated another way, reliability can be seen as:

11. What is MTBF Mean time between failures ( MTBF ) describes the expected time between two failures for a Repairable system . It is expressed in Hours and is equivalent to expected number of operating hours before a product fails. Higher MTBF numbers indicate a higher reliability of a product or system

12. What is MTTR Mean Time To Repair ( MTTR ) is the time needed to repair a failed hardware. It is expressed in Hours and does not include lead time for parts not readily available . MTTR can tell you: Repair OR Replace , Training Better , Processes

13. What is MTTF Mean time to failures ( MTTF ) defines the mean time expected until the first failure of a piece of equipment or in another words it is the mean time device remains operation before it fails. It is a basic measure of reliability for Non-Repairable systems and should be as long as possible. Mean Time to Failure can be used for: Inventory lead time , Quality control , Misuse of equipment Formula : MTTF :- Total hours of operation / total number of units .

14. What is OEE Overall equipment effectiveness  ( OEE ) is a measure of how well a  manufacturing  operation is utilized (facilities, time and material) compared to its full potential, during the periods when it is scheduled to run. it identifies the percentage of manufacturing time that is truly productive. An OEE of 100% means that only good parts are produced (100%  quality ), at the maximum speed (100%  performance ), and without interruption (100%  availability ) OEE is calculated with the formula (Availability)*(Performance)*(Quality) Availability :  percentage of scheduled time that the operation is available to operate. Often referred to as Uptime. Performance:  speed at which the Work Center runs as a percentage of its designed speed. Quality :  Good Units produced as a percentage of the Total Units Started. It is commonly referred to as the  first pass yield  (FPY).

15. Availability Availability of a system may also be increased by the strategy of focusing on increasing testability, diagnostics and maintainability and not on reliability. Improving maintainability during the early design phase is generally easier than reliability (and Testability & diagnostics). Maintainability estimates (item Repair [by replacement] rates) are also generally more accurate. when reliability is not under control, then many and different sorts of issues may arise, for example The need for complex testability (built in test sensors, hardware and software) requirements, The need for detailed diagnostic procedures, Manpower (maintainers / customer service capability) availability, Spare part availability, Dead on arrival issues (non-quality impact on system availability), Logistic delays of spares or manpower due to any reason, Lack of repair knowledge and expert-personnel Extensive retro-fit and complex configuration management costs and others.

16. Conclusion In summary, an effective industrial maintenance program is not merely about fixing equipment when it breaks. It is a strategic, data-driven function essential for operational excellence. By moving away from costly reactive methods and embracing a structured  Preventive Maintenance  approach, we can significantly enhance equipment  Reliability . MTBF, MTTR, and OEE  provide us with the visibility to measure our performance, identify areas for improvement, and make informed decisions. Ultimately, a robust maintenance strategy minimizes unplanned downtime, reduces long-term costs, and ensures a safer workplace, directly contributing to achieving our production goals and maintaining a competitive edge. Let's commit to implementing these principles for a more reliable and productive operation.

17. https://accendoreliability.com/impact-of-maintenance-strategy-on-production-efficiency-and-quality/ https://upkeep.com/learning/run-to-failure-maintenance/ https:// www.atlassian.com /incident-management/ kpis /common-metrics Reference

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