1.

0 MAINTENANCE
Electrical safety
 Objective
Objectives of Electrical Safety :
Be familiar with the fundamental concepts of electricity.
Be familiar with the effects of electricity on the human body.
Be able to recognize common electrical hazards.
Be familiar with electrical protective devices
 IMPORTANCE ELECTRICAL
SAFETY
Safe working environment and operation of electrical installations
Safe use of electricity & electrical equipment
Safety of working personnel-electrical technical person and workers
Safety standards of electrical installations & equipment.
 TYPES OF ELECTRICAL
INJURIES
There are four main types of electrical
injuries:

Electrocution (death due to electrical shock)

Electrical shock
Burns
Falls
Electric Shock Effect
ON SITE ELECTRICAL SAFETY
Inspect your work areas
o Existing unsafe conditions
o Bare wires
o Open enclosures containing exposed wires
o Loose or missing covers or fasteners

Use good electrical safe practices

o Use a certified safe electrical equipment /appliance.
o No overloading outlets
o Pull on plug, not cord to disconnect appliance
 WORK AREA CONTROL
Protective Equipment
 Use goggles and breathing masks.

Tidiness
 Dispose of sharp objects, blades, glass shards in suitable containers -
Ensure the workshop is tidy.

Machinery
 Make sure machinery is properly installed, levelled and are periodically
maintained or serviced.
Electricity regulation 1994
 Electricity regulation 1994
Regulation 110. Inspection and test for the
purpose of maintenance of installation, etc.

(1) An installation shall be maintained in good and working

order and safety precautions shall be observed at all times to
prevent danger.
(2) The responsibility to maintain the installation in the
manner required in sub regulation (1) shall be with the
owner, management, licensee or occupier of the
installation, his servant or agent ,as the case may be.
(3) An installation, other than a domestic installation, shall be
checked and tested by a competent person at least once in every
five years, or at any time as directed by the Commission.
 Electricity regulation 1994
(4) Any protective relay and device of an installation shall
be checked, tested and calibrated by a competent person at
least once in every two years, or at any time as directed by the
Commission.

(5) The Commission may inspect an installation or the premises

where an installation is located if the Commission thinks it is
desirable to do so in the interest of the public or for public safety
and if a notice in writing is given to the owner, management or
licensee of an installation or any premises, the owner,
management or licensee of the installation or premises,
as the case may be, shall cause the person in charge of the installation
or premises to attend and give such assistance as may be
ordered by the Commission in the notice.
 Electricity regulation 1994
Regulation 111. Competent person to undertake maintenance
work.
No person, except a competent person or a person
acting under the control of a competent person, shall
undertake to carry out any repair, replacement,
servicing or cleaning of any equipment which forms
part of an installation.
 Electricity regulation 1994
Regulation 112. Adequate safety precautions
to be taken during work.
(1) A competent person shall take adequate
precautions to prevent any installation or
equipment from being accidentally or
inadvertently made alive when persons are
working.
(2) Any person engaged in work in connection with
any installation or equipment shall be
adequately protected from danger, and the
responsibility for such protection shall be on
the licensee or supply authority, owner ,
management or occupier of the installation, his
servant or agent, as the case may be.
 Electricity regulation 1994
(3) Where any person is engaged in work on a circuit controlled by
a switch not under his immediate supervision, the switch shall be
locked in "OFF" position until the work is finished and—
(a) in the case of aerial line work, a notice
shall be hung on the switch and earthing
sticks to provide earthing shall be fixed at a visible
distance from the workmen; and
(b) in the case of underground cabling work, a
suitable notice shall be hung on the switch, to warn
any person that there are persons at work on the circuit and
that the switch shall not be closed.
 Electricity regulation 1994
(4) If the circuit is operated at high voltage or extra high voltage,
the switch in subregulation (3) shall be locked in the "OFF"
position by the competent person.
(5) No competent person or person under the control of a
competent person shall reclose any switch until he is certain that all
persons are clear of the circuit concerned and have been
warned that the circuit is to be made alive.
(6) No person shall defeat, remove or damage a safety
device fitted in connection with or for use with any installation or
equipment.
 Electricity regulation 1994
(7) Notwithstanding subregulations (1),(3),(4) and (5), where
the competent person is satisfied that live work on any installation,
equipment or circuit, as the case may be, is safe, it shall
not be unlawful for any person to engage in such work.

Regulation 113. Competent person to issue written instruction.

No work or operation under the control of a competent person shall be
commenced until a written instruction has been issued by the
competent person
 Safety Precautions to Avoid
Electrical Accidents
Don’t directly touch the person who is still in contact with live
conductor.
Live wire connection.
 Grounding.
 Insulation strength.

Plug point disconnection. (when unused)

 Install switches-to avoid open, unprotected ends of wire.
Use fuses & other protective devices to avoid damage to the
equipment.
Wear a proper attire during working.
Clothing and Personal
Protective Equipment
 Grounding
To connect the neutral of an electrical system to the ground is called
grounding.
Electrical equipment safety.
Internal and external factors make the electric system unbalance, to
avoid this distortion and damage to the system.
Safety Regulations
Equipment Personnel Environment

Personal
Ambient
Insulation Knowledge and
Conditions
experience

Personal
Grounding Mental
Condition

Equipment
Status
 Safety Regulations
Insulation
 Dielectric strength of the insulation.
Grounding
 Electrical equipment should be properly grounded.
Equipment Status
 Good condition
 Use proper equipment for the job.
Personal Mental Condition
 Should not be mentally disturbed.
Personal Knowledge and experience
 Should be properly trained for the activity, he has to perform.
Ambient Conditions
 The conditions under which the equipment works efficiently.
 Current rating, Voltage rating, Frequency, Temperature.
1.0 MAINTENANCE
 MAINTENANCE
Maintenance Definition
British Standard Glossary of terms (3811:1993) defined
maintenance as:
the combination of all technical and administrative
actions, including supervision actions, intended to retain
an item in, or restore it to, a state in which it can
perform a required function.
Maintenance Definition

maintenance is a set of organised activities that are

carried out in order to keep an item in its best operational
condition with minimum cost acquired.
Maintenance Activities
Activities of maintenance function could be either
repair or replacement activities, which are necessary
for an item to reach its acceptable productivity
condition and these activities, should be carried out
with a minimum possible cost.
Maintenance Objectives
PLANT

Maximising Production Reduce Breakdowns

M
A
Minimising Energy I Reduce Downtime
Usage N
T
Optimising Useful Life Improving Equipment
of Equipment
E Efficiency
N
Providing Budgetary A Improving Inventory
Control N Control
C
Optimising Resources E Implementing Cost
Utilisation Reduction

Figure 2.3 Maintenance

Objectives
Maintenance Objectives
 Improving equipment efficiency and reducing scrap rate.

 Minimising energy usage.

 Optimising the useful life of equipment.

 Providing reliable cost and budgetary control.

 Identifying and implementing cost reductions.

Maintenance Expectation
REDUCE UNSCHEDULED BREAKDOWNS

INCREASE IN OPERATING LIFE OF THE ASSETS

PREDICT LIFE SPAN OF THE MACHINE

MAXIMIZING EQUIPMENT EFFECTIVENESS

SPARES INVENTORY CONTROL

EFFECTIVE MAINTENANCE
RESTORE
SYSTEM
PRODUCTIVITY
IMPROVES INCREASE
EQUIPMENT PLANT
RELIABILITY PROFIT

INCREASE OF MAINTAINED
EQUIPMENT
EFFECTIVE PRODUCT
EFFICIENCY MAINTENANCE QUALITY

AVOID IMPROVE
UNNECESSARY OVERALL PLANT
SHUTDOWNS EFFECTIVENESS
PROLONG
SYSTEM
LIFE
Effect Without Maintenance

INCREASED MAINTENANCE AND REPAIR COST

REDUCED SYSTEM / EQUIPMENT LIFE

INDUCED / CREATED UNWANTED WASTE

CAN AFFECT PRODUCT QUALITY

REDUCED PLANT PRODUCTIVITY AND PRODUCTIVITY

 Maintenance Benefits

Lower
Operating
Reduced costs
inventory

Continuous Improved
improvement Maintenance quality

Higher Improved Faster, more

productivity capacity Dependable
throughput
 Classify type of maintenance :
 Fault Maintenance
 do any maintenance when the damage occur during machine operation)

 Protective Maintenance
 To make sure the machine are in good condition
 If the necessary for the repair of damage

 Modification Maintenance
 Is the equipment according to the current need

 Service List Maintenance

 The process in terms of maintenance equipment for the inspection schedule
follows
 Suitability of equipment/ machinery
 To extend of lifetime of the machine
 Classify types of maintenance
Fault Maintenance

Defect that may or may not cause a failure of component or

system. A fault that occurs intermittently is transient fault, one
that persists after its occurrence is a solid fault

Protective Maintenance

Systematic inspection, detection, correction, and prevention of

incipient failures, before they become actual or major failures.
Contrasted with corrective maintenance.
 Classify types of maintenance
Modification Maintenance

Change that adapts, limits, qualifies, or restricts something to a

new end or purpose. See also alteration.

Service List Maintenance

Level of maintenance that requires planning, allocation of

significant amount of time, and high degree of coordination
between different departments, and is typically initiated
through a work order
 Different type of
maintenance: Running
maintenance
Preventive Shutdown
Maintenance maintenance
Scheduled
maintenance
Planned
Maintenance Breakdown
Maintenance

Corrective maintenance
Maintenance Shutdown
Predictive maintenance
Maintenance
Unplanned Emergency
maintenance maintenance
Maintenance Management
Maintenance Management is defined as
the organization of maintenance within an
agreed policy.
Maintenance Policy is a statement of
principle used to achieve maintenance
objectives and guide Maintenance
Management decision making.
 Maintenance
Management

Record Schedule Cost Organization

 Maintenance Record
Maintenance records are written notes that provide documentation
about the upkeep of a certain piece of equipment or maintenance
activities.
The functions of records maintenance include the following essential
components:
Organizing and filing records
Identifying which records to retain, and for how long
 Maintenance Record
Recommended forms :
• Daily groomer operator’s log form;
• Grooming equipment maintenance request
• Vehicles/equipment reports and maintenance records
• Corrective action form

Record equipment details

• Consider including equipment types, number and date purchased, any
identifying making intended usage and usage restrictions retirement
information, safety concerns
Record regular maintenance
Record calibration of all gauges and meters
 Benefits :
Greater Safety
Decreased production down time
Less cost for simple repairs
Better spare parts control
Proper Indentification of items
Less standby equipment required
Fewer large scale and repetitive repairs
Maintenance Scheduling
To make observation of the maintenance process and the date/time of
maintenance.
(Scheduling refers to timing and sequences of operations.)

 Why do we need maintenance scheduling?

 make it easy to analyze about the malfunction frequency of some

equipment,
types of malfunction,
when the malfunction of the equipment occur
the ways to overcome the malfunction.

(It is an important segment of the production planning and control

activity as well as the service operations like plant maintenance)
 Maintenance Scheduling
To make observation of the maintenance process and the date/time of
maintenance.

(Scheduling refers to timing and sequences of operations.)

 Maintenance Scheduling
 Why do we need maintenance scheduling?

• make it easy to analyze about the malfunction

1 frequency of some equipment

• types of malfunction
2

• the ways to overcome the malfunction

3

• when the malfunction of the equipment occur

4
Importance Scheduling
Equipment can be utilized effectively
Eliminates undue interruptions in the production flow
Eliminates chances of sudden breakdown
Facilities proper sequence I maintenance service
Facilitates optimun use of highly paid maintenance staff
Preventive maintenance
Maintenance Execution Effectiveness
schedule Verification
Service Request

Allocated Authorized data

scheduled tasks Acces collection

Maintenance manager
and technical staff
Maintenance Costs
Maintenance cost include :

Cost to
replace or Losses of
repair output

Delayed Scrap and

shipment rework
Maintenance Costs
Cost associated with maintenance are:

Downtime (Idle time cost) cost due to equipment breakdown.

Cost of spares or other material used for repairs.

Cost of maintenance labour and overheads of maintenance

departments.

Losses due to inefficient operations of machines.

Maintenance Costs
Cost

Breakdown Cost

◦ Maintenance
Commitment
Maintenance Costs
Cost

PM Cost

Breakdown Cost

Maintenance
Commitment
Maintenance Costs
Cost
Total Maintenance Cost

PM Cost

Maintenance
Commitment
Maintenance Costs
Cost
Total Maintenance Cost

PM Cost

Breakdown Cost

Optimal Maintenance
Commitment
Maintenance Organization
Maintenance Hierarchy
Maintenance Manager
Monitor the development and productivity of every unit. Carry
out of supervision based on the report made by the technical
manager.

Technical Manager
Give order to every unit based on order of maintenance
manager. Solve any problems from any unit before the problems
will be referred to maintenance manager

Site Support
Contact suppliers or contractor if there maintenance which
required of special expertise. Are going to act of service
employee unable to overcome problems.
Reason maintenance department need get help the outside
maintenance team
Maintenance Versus
Organization Objectives
A system is a collection of components that work
together towards a common objective.
Maintenance can be considered as a system with a
set of activities carried out in parallel with
production systems. A diagrammatic relationship
among organizational objectives, the production
process, and maintenance is shown in Figure 1.1
 V ariations in
Maintenance
Demand

PLANNING ORGANIZING
Job Design
Maintenance Philosophy
Standards
Maintenance Load Forecasting
INPUT Maintenance Capacity
Work Measurement OUTPUT
Maintenance Organization
Maintenance Project Management
Facilities
Maintenance Scheduling
Process MONITOR
Operational
Labor Machines
Equipment &
Spares Equipment
Management
* Scheduling

FEEDBACK
CONTROL
Work control
Material control
Inventory control
Cost control
Managing for quality
Maintenance System Output
Amaintenance system can be viewed
as a simple input output model. The
inputs to such a model are labor,
management, tools, spares,
equipment, etc. and the output is
equipment that is up, reliable and well
configured to achieve the planned
operation of the plant.
 Maintenance Planning
activities
Planning activities generally include the
following :
1. Maintenance philosophy
2. Maintenance load forecasting
3. Maintenance capacity
4. Maintenance organization
5. Maintenance scheduling.
 MAINTENANCE STRATEGIES
(MAINTENANCE FORM)
1.Breakdown Maintenance (Run To Failure)
2. Fault Finding (FF)
3. Time directed Preventive Maintenance(TD)
4. Condition Based Maintenance (CBD)
5. Design Modification (DM)
6. Replacement Instead of Maintenance
7. Planned Replacement (Car Fleet)
8. Opportunity Maintenance
Maintenance Load Forecasting
Maintenance load is a random variable and
forecasting is the process by which maintenance
load is predicted. Load forecasting is essential for
capacity planning. Many factors affect the load,
they include equipment age, climate, quality of
maintenance, etc.
 Information on most recent
maintenance load demand and
backlog of maintenance work

Maintenance
load forecasting

Maintenance Maintenance Controlling

capacity planning scheduling maintenance system

Output of
maintenance system
Maintenance Scheduling
Maintenance scheduling is the process of assigning
resources and manpower for jobs to be
accomplished at certain times. It is necessary to
ensure that the needed craftsmen, the parts, and
materials required are available before a
maintenance task can be scheduled.
Maintenance Capacity
Planning
Maintenance capacity planning determines the
resources needed to meet the demand for
maintenance work. Those resources include
manpower, material, spare parts, equipment, and
tools. Critical aspects of maintenance capacity are
the numbers and skills of craftsmen, required
maintenance tools, etc.
Maintenance Organization
Maintenance Organization Depends On
Maintenance Load, Plant Size, Trade and Skill,
Maintenance Could Be Centralized Or Decentralized
Or A Combination of Both. See Figure 1.5 In Text
Book
Production
area A

Maintenance Overload
for production
area A

Production
area B

Maintenance
Overload Central
for production
maintenance
area B
unit

Overload

Production
area C Outside
contractor
help
Maintenance Overload
for production
area C
 Organizing Activities
1. Job Design

2. Standard Time

3. Project Management
Job Design
Job design, as related to maintenance work,
comprises the work content of each job and deter-
mines the method that is to be used, special tools
needed, and the skilled persons required.
Time Standards
Time Standards are Needed For Effective Planning.
It is The Time That Takes A Qualified Worker
Worker At 100% Pace To Complete The Job.
Techniques Used For Developing Time standards
Are Work Measurement, Work Sampling.
Estimation and Slotting
Project Management
Techniques Such As CPM, PERT Are Needed For
Large Jobs Such as Overhauls.
They will Enable Better Control OF Cost and work.
They Usually Results In Better Utilization Of
Resources
Control activities
Control is an essential part of Scientific
management. control as applied to maintenance
includes:
1. Work control
2. Inventory control
3. Cost control
4. Quality control
 Work Control
The management and control of the maintenance
work is essential for achieving set plans. The work
order system is the tool used for controlling the
maintenance work. A well designed work order
with a sound reporting system is the heart of the
maintenance system The essential tools for
effective control of the maintenance work including
the design of a work order are covered in chapter
2.
Inventory Control
Material and spare parts are essential for
maintenance work. Prior to scheduling
maintenance work spare parts must be available.
Techniques for inventory control are covered in
chapter 7 of the text
 MAINTENANCE COSTS.
1. DIRECT COSTS
◦ Cost of Periodic Inspection
◦ Service Cost
◦ Repair Cost, Overhaul Cost

2. STAND-BY COSTS
◦ Cost of Operating and Maintaining a Standby Unit
 MAINTENANCE COSTS.
3. LOST PRODUCTION COSTS :
◦ Cost due to Equipment down time.

4. DEGRADATION COST
◦ Cost occurring due to deterioration of the life span of equipment due to no
maintenance or inadequate maintenance.
Cost Control
The control of maintenance cost optimizes all the
costs in maintenance, while achieving, set
organizational objectives such as: availability,
“Quality Rate”, and other efficiency and
effectiveness measures. Cost reduction and control
can be used as an edge for competition in providing
products and services. The issues related to cost
and its control are presented in chapters 2 and 10
Quality Control
In the case of maintenance work "doing it right the
first time" is very essential. Quality may be
assessed as the percentage of accepted
maintenance jobs according to the standard
adopted by the organization. High Quality is usually
assured by checking the critical maintenance jobs
or by maintenance supervision. The details of
maintenance quality control are presented in
chapter 8.
Managing For Quality and
Training
Managing for quality is a managerial responsibility..
The key for managing for quality lies first in the
awareness of the need to improve and second in
selecting appropriate improvement techniques.
Chapter 12 focuses on the aspects of continuous
improvement.
Human Behavior
Managers should try to know how the behavior of
subordinates can affect management's planning,
organizing, and controlling actions. In maintenance
decision making, behavior of subordinates should
be of interest to management. It should be ensured
that the desired level of craftsmen satisfaction is
achieved and maintained.
 Maintenance Terms
Availability: The ability of an equipment to
successfully perform its required function at
a stated instant of time or over a stated
period of time.

Breakdown: Failure resulting in the non-

availability of an equipment.
 Maintenance Terms
Condition-based maintenance: The preventive
maintenance initiated as a result of knowledge
of the condition of an equipment observed
through routine or continuous monitoring.

Condition monitoring: The continuous or

periodic measurement and interpretation of
data to infer the condition of an equipment to
determine its need for maintenance.
 Maintenance Terms
Corrective maintenance: The maintenance
carried out after a failure has occurred and
intended to restore an equipment to a state
in which it can perform its required function.

Emergency maintenance: That maintenance

which is necessary in order to avoid serious
consequences, such as loss of production
time and unsafe conditions
 Maintenance Terms
Failure: The termination of the ability of an
equipment to perform its required function.

Fault: An unexpected deviation from

requirements which require corrective
action.
 Maintenance Terms
Feedback: A report on the success or failure
of an action to achieve its desired objectives and
which can be used to improve a process.

Forced outage: Outage due to the unscheduled

stopping of equipment
 Maintenance Terms
Inspection: The process of measuring,
examining, testing, gauging or otherwise
detecting any deviations from specifications.

Maintainability: The ability of an equipment,

under stated conditions of use, to be retained in,
or restored to, a state in which it can perform its
required function, when maintenance is performed
under stated conditions and using prescribed
procedures and resources
 Maintenance Terms
Maintenance: The combination of all
technical and and associated actions by
which an equipment or a system is kept or
restored to a state in which it can perform its
designated functions.

Maintenance history: A history record

showing repair, spares, etc. used to assist
maintenance planning.
 Maintenance Terms
Maintenance schedule: A comprehensive
list of items and the maintenance tasks
required, including the intervals at which
maintenance should be performed.

Planned maintenance: The maintenance

organized and carried out with forethought,
control, and the use of records to meet a
predetermined plan
 Maintenance Terms
Overhaul: A comprehensive examination and
restoration of an equipment, or a major part
There of, to an acceptable condition.

Preventive maintenance: The maintenance

carried out at predetermined intervals or
intended to minimize the probability of failure
or the performance degradation of equipment.
Maintenance Terms
Refurbishment: Extensive work intended to bring
equipment up to acceptable functional conditions,
often involving improvements.

Repair: To restore an item to an acceptable

condition by the renewal, replacement or
replacement of damaged or worn parts.
 Maintenance Terms
Restoration: Maintenance actions intended
to bring back equipment to its original
conditions

Running maintenance: Maintenance which

can be carried out whilst the equipment is in
service.
 Maintenance Terms
Shut down maintenance: Maintenance which
can only be carried out when the equipment
is out of service.

Spare stock: Items which are available for

maintenance purposes or for the replacement
of defective parts.
 Maintenance
Work Terms giving
order: A written instruction
detail of work to be carried out including
detail of spares, manpower, etc.

Work requisition: A document requesting

work to be carried out

Work specification: A document describing

the way in which the work is to be carried
out. It may define the materials, tools, time
standards, and procedures.
EFFECTIVE MAINTENANCE
RESTORE SYSTEM PRODUCTIVITY
IMPROVES EQUIPMENT RELIABILITY
AVOID UNNECESSARY SHUTDOWNS
INCREASE OF EQUIPMENT EFFICIENCY
PROLONG SYSTEM LIFE
IMPROVE OVERALL PLANT EFFECTIVENESS
MAINTAIN PRODUCT QUALITY
INCREASE PLANT PROFIT
NON-EFFECTIVE MAINTENANCE
INCREASED MAINTENANCE COST
REDUCED SYSTEM / EQUIPMENT LIFE
INDUCED / CREATED UNWANTED WASTE
ADDITIONAL COST TO CLEAN THE EQUIPMENT
CAN AFFECT PRODUCT QUALITY
REDUCED PLANT PRODUCTIVITY
DOWNGRADED SYSTEM EFFECTIVENESS
DECREASED PLANT PROFIT
POOR SKILL LEVEL
REPITITIVE FAILURE
Extra
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