The Main concepts and definitions for Maintenance .ppt

Maintenance Main Concepts and Definitions

1. TROUBLESHOOTING OF
MECHATRONICS
SYSTEM
MSE5532
MAINTENANCE
MAIN CONCEPTS AND
DEFINITIONS

2. WHAT IS MEANT BY
TROUBLESHOOTING?
Troubleshooting is a systematic approach to
solving a problem.
It is often used to find and correct issues with
complex machines, electronics, computers and
software systems.
The goal of troubleshooting is to determine why
something does not work as expected and
explain how to resolve the problem.
The first step in the troubleshooting process is
to describe the problem completely.

3. WHAT IS MEANT BY
MAINTENANCE ?
Maintenance refers to the actions taken to keep
equipment, machinery, or a facility in good
working condition and ensure its safety for use.
Maintenance activities are done to prevent
potential issues or breakdowns.

4. •Machine Fault: means that the machine is unable to give the
anticipated function. (This is concerned with the machine as a
whole).
•Failure: Means that the material of certain part fractured or
exceeds elastic limit. (this needs Root Cause Analysis, and
failure cause determination knowledge).
•Fault Diagnoses: determination of the failed element before
disassembly of the machine.
•Fault Prediction: estimation of the approximate time of failure
in order to prepare for the proper repair operations.
1. Important Definitions: 1. Important Definitions:

5. •Monitoring: means that the machine condition is detected
continuously through using some detecting apparatus.
•Reliability: = 1 – Failure rate
•Maintainability: Measure the ability of the system to be maintained .
It is the product design and development directed to facilitates the
maintenance operations. Maintainability of a machine is good if
doing maintenance operations are easy in not needing high cost. It
also means keeping machine in good condition, try not to have
failure.

6. •System life cycle: this is the cycle which any product go through: it
starts with just a concept or idea then preliminary design then detailed
design, then first prototype, then modified prototype, then product.
•In each phase of system life cycle product maintenance must be
considered and shown how could it be done.
•Part Supportability: this is concerned with spare parts availability and
inter-changeability.
•Maintenance Strategies: this is methodology by which the machine will
be maintained (will be shown later).

7. •Maintenance Management is defined as the organization of
maintenance within an agreed policy.
•This policy defines the acceptable condition of maintenance.

•The Maintenance Manager
•A manager gets his work done with and through other people using
his managerial skills, namely, technical, human and administrative
skill.
•Management functions are:
•Planning
•Organizing
•Controlling
•Directing (Leading, Motivating, Communicating, Persuading,
Training,...).
2.1 MAINTENANCE MANAGEMENT2.1 MAINTENANCE MANAGEMENT

8. 2.2 THE DUTIES OF A MAINTENANCE DEPARTMENT2.2 THE DUTIES OF A MAINTENANCE DEPARTMENT
•The duties of a maintenance department vary from company
to company, and often from factory to factory within the same
company.
•The scope and depth to which it executes its duties depends
upon company policy, size and type of plant, type of
production and skilled labor available.
The maintenance manager typically will be responsible for The maintenance manager typically will be responsible for
five main functions: five main functions:
1.Plant maintenance,
2.Maintenance planning and control,
3.Work services,
4. Central workshops,
5. Maintenance stores,

9. Usually, the work which the department undertakes Usually, the work which the department undertakes
may be divided into four main groups: may be divided into four main groups:
1.1.Pure maintenance, Pure maintenance,
2. Installation and alteration of plant, equipment 2. Installation and alteration of plant, equipment
and services. and services.
3.Operation and supervision of particular 3.Operation and supervision of particular
utilities and special services. utilities and special services.
4. Various duties assigned to the 4. Various duties assigned to the
maintenance departmentmaintenance department

10. Maintenance in terms of plant operation this Maintenance in terms of plant operation this
means that: means that:
a)The plant must be available for start-up when required.
b) The plant must not break down during production runs.
c) The plant must operate in an efficient manner at the
required level of production.
d) The downtime for maintenance must not interfere with
production schedules or runs.
e) The downtime which may be caused by a breakdown
should be a minimum.

11. To accomplish the above conditions:To accomplish the above conditions:
a)There must be complete co-operation and mutual
understanding between maintenance and production
departments.
b) There must be an effective maintenance policy for
planning, controlling and directing all Maintenance
activities.
d) The maintenance department must be well organized,
adequately staffed and the personnel sufficiently
trained to carry out the work.

12. 1.Maintenance organization i.e., centralized versus decentralized
maintenance.

2.In-house versus outside contracting maintenance.
3.Preventive versus predictive maintenance.
4.Repair versus replacement.
Some of these aspects will be discussed in the following sections.
In general the following items represent the main In general the following items represent the main
aspects of maintenance philosophy or policy:aspects of maintenance philosophy or policy:
MAINTENANCE PHILOSOPHY (POLICY) (cont.) MAINTENANCE PHILOSOPHY (POLICY) (cont.)

13. Involve the assignment of duties and the coordination of efforts
among all organizational personnel so as to ensure maximum
efficiency in the attainment of predetermined objectives.
MAINTENACE ORGANIZATION:
Definition:Definition:
•Geographic locations - Functions - Products - Projects - Size
of organization -Top management philosophy -Capital or
budget available
Variables Affecting Organization Structure:Variables Affecting Organization Structure:
Two main types of organizations are available:
1. Centralized organization
2. Decentralized organization
Types of Organizations:

14. Management
Economy, Purchase,
etc. ( Staff-
functions).
Production A Production B Maintenance
Maintenance
Engineer
Foreman
Production
Engineer
Foreman
Production
Engineer
Foreman
Fig (1-1) A Centralized Maintenance

15. Management
Economy, Purchase,
etc. ( Staff-
functions).
Production A Production B
Production
Engineer
Foreman
Production
Production
Engineer
Foreman
Production
Foreman
Maintenance
Foreman
Maintenance
Fig (1-1) B Decentralized Maintenance

16. •Any maintenance strategy are included in the following categories
1.Breakdown Maintenance
2.Scheduled Shutdown Maintenance
3.Preventive Maintenance
4.Predictive Maintenance
5.Reliability Centered Maintenance
6.Total Productive Maintenance
MAITENANCE STRATEGY

17. 1. Breakdown Maintenance (BM)
Breakdown maintenance is the most primitive form of maintenance
strategy, (it is sometimes called Corrective Maintenance, too).
Maintenance is done only when there is part failure.
This could be done only for not effective parts that I have a replacement
for them.
This type can not be done for critical expencive machines (turbines, blast
furnace…)

18. 2. Scheduled Shutdown Maintenance (SSM)
•Scheduled shutdown maintenance is also one of the oldest strategy for
the maintenance of refinery plants or facilities.
•A certain part of the plant is shut down and maintenance operations
are done

19. 3. Preventive Maintenance
•The concept of Preventive Maintenance (PM) was introduced
for the first time in the 1950s.
•Preventive maintenance is work carried out at predetermined
intervals or when indicated by Predictive Maintenance or
functional criteria and is intended to increase the possibility
to keep equipment in some stated operating condition.
•In early stage, Preventive Maintenance had been very
advanced strategy and many factories approved it.
•However later, it became to be criticized in the point of over
maintenance.
•Suitable applications for Preventive Maintenance, typically,
would be large, high speed rotating machinery, unspared unit
charge pumps, condensers and coolers, electric switch gear,
motor and critical instrumentation.

20. •Predictive Maintenance was introduced around 1970 to improve
the defect of over maintenance that Preventive Maintenance
inherently held,
• Predictive Maintenance is the application of measurement
techniques, designed to provide information on the current
condition of equipment or system so as to allow the timing and
extent of preventive maintenance to be decided on a rational
basis.
•Such techniques include vibration Analysis , Lubricating Oil
Analysis , corrosion measurement activities , Ultrasonic Test,
Radiograph Test, ... Etc.
•This category of maintenance is also called "Condition Based
Maintenance" in contrast with that Preventive Maintenance is
called "Time Based Maintenance".
4. Predictive Maintenance

23. Table 1-2. Comparison of preventive and predictive maintenance
Actions
Preventive
maintenance
Predictive
maintenance
Diagnosis and
inspection
Uses repair history to
predict equipment life
Standard PM inspections
and services to extend
equipment life
Uses diagnostic tools
Compares current
operation to normal
operating profile
Detecting abnormal
conditions
Visual or tear-down
inspections, evaluating
equipment history,
estimating failure point
Monitoring during
operation Automatic
warning of failure
Correcting
deficiencies
Component replacement,
periodic overhaul
Spot replacement of bad
components only
Cost of repair
Chance of replacing good
components Possible
overstocking of parts
More accurate
inventory