Maintenance & Safety Engineering

Department of Mechanical
Engineering
College of Engineering Roorkee
 Contents
• Introduction
• operating life cycle,
• Failure data analysis, failure rate curve, hazard
models.
• maintainability,
• availability,
• reliability
 Introduction

• Industry today is in a fight to survive. Competition is found

not only on a domestic level, but also on international levels.
In an effort to survive, all forms of production analysis,
product reviews, and material reviews are made and
periodically checked. Statistical process control is only one of
the new methods used to reduce operational costs. However,
one area many industries are now turning their attention
toward is the maintenance function.
 Introduction (Cont..)

• Cost reduction in maintenance does not necessarily mean a

reduction in service or in the quality of service. It means a
better control of the maintenance organization and the related
areas. To properly control the maintenance of any facility,
information is required to analyze what is occurring.
Manually, this requires a tremendous amount of effort and
time. In recognition of this, many of the progressive
companies are developing and using computer programs
geared toward control of the maintenance organization. These
systems are often referred to as computerized maintenance
management systems (CMMS).
 What is Maintenance? What is Ma What is
maintenance ?intenance?

• Maintenance - any activity carried out on an

asset in order to ensure that the asset continues
to perform its intended functions, or to repair
the equipment. Note that modifications are not
maintenance, even though they may be carried
out by maintenance personnel.
• Keeping equipment's available, reliable and
cost optimized
 Asset?
• Asset - unlike in the accounting definition, in
maintenance this is commonly taken to be any
item of physical plant or equipment
• It is the basic unit of maintenance.
 Asset Management
• Asset Management - the systematic planning
and control of a physical resource throughout
its life. This may include the specification,
design, and construction of the asset, its
operation, maintenance and modification while
in use, and its disposal when no longer
required.
 Maintenance function?
• The maintenance department has a
more involved list of functions or
responsibilities. These can be grouped
into five main areas:-

1. Maintenance of existing equipment.

2. Equipment inspection and services.
3. Equipment installation.
4. Maintenance storekeeping.
5. Craft administration.
[Link] of Existing Equipment
 Maintaining existing equipment is the basic reason for the
department.
 The maintenance group will make repair to the production
equipment as quickly and economically as possible. They
should be able to anticipate repairs, based on previous
experience with the equipment.
 To prevent rapid wear of the equipment, the group should
utilize cost-effective preventive maintenance programs.
 To perform these tasks as efficiently and cost effectively as
possible requires the utilization of a trained workforce and the
use of modern tools and maintenance methods that are
available.
 However, performing all of the above tasks depends on one
important item accurate record keeping. Without accurate re­
cords, it will not be possible to complete the assigned tasks in
a timely and cost-effective manner.
 2. Equipment Inspections and Service

 This task will require the engineer or manufacturer to

determine the proper lubricant for the equipment. In
addition to the type of lubricant, the proper amount
and time intervals of application of the lubricant are
necessary. The inspections are required to ensure that
the equipment is in safe operating condition and is
being serviced in a timely manner.
 Some installations will require that the operational
personnel do some routine lubrication and servicing.
Even where this is a common practice, the
maintenance department should oversee the
completion of the tasks.
 3. Equipment Installation

 This responsibility varies from industry to

industry and depends on the size of the
installation and the maintenance workforce.
 Some industrial facilities that require
constant equipment changeover may have
an installation department.
 When large installation projects occur in
some industries without the necessary
workforce, outside contractors are used to
supply the needed manpower.
 4. Maintenance Storekeeping

 This responsibility of the maintenance group involves the

receiving and distribution of the spares necessary for the
repair and upkeep of the plant equipment.
 There are several important tasks involved in this
responsibility. The first is recording the necessary spares for
each piece of equipment. With all of the spares recorded,
the maintenance group has the responsibility of setting the
inventory level for each part. As the spares are used, the
replacements will have to be ordered.
 The ordering process is important to prevent material
outages in the stores. Material outages could result in
production delays, if equipment breakdowns occur and no
replacement parts are available. Keeping the stores
inventory level as low as possible will prevent tying up
capital investments in spares.
 5. Craft Administration

 This is the responsibility of controlling the

manpower used by the maintenance department.
 The most cost-effective way of determining the size
of the workforce is the work in the maintenance
backlog. By looking in the backlog, the number of
employees for each craft area can easily be
determined. As programs are changed and
equipment is added or deleted from a department,
the workforce can be adjusted as necessary.
 The responsibility for providing the necessary tools
and supplies for the crafts is also included in this
area.
 Concept of Maintenance

• Care and upkeep of any machinery, equipment, facility or

property.

• Old concept of Maintenance: “Maintenance is about

preserving physical assets.”

• New concept of Maintenance: “Maintenance is about

preserving the function of assets.”
 Definition
Maintenance is any activity designed to keep
equipment in working condition.
Maintenance covers a group of activities performed on
an equipment so as to achieve consistently desired
performance for the equipment, over its designed
life.
Maintenance can be considered as a combination of
actions carried out in order to replace , repair,
service, and modify components of manufacturing
plant so that it will continue to operate to a specified
availability.
Maintenance must be effectively used to obtain the
highest availability of production equipment
commensurate with maintenance cost. Two groups
of maintenance departments-
Building and grounds: includes electrician welders,
pipe fitter, painter, car painters etc.
Equipment Maintenance group: Includes workers, such
as mechanics, machinists, oilers, electricians etc.
 Maintenance Objectives
1. To keep the maintenance cost per production
item produced as low as possible.
2. To keep the quality of the product very high.
3. To keep the downtime for critical equipment
as low as possible.
4. To keep maintenance cost as low as possible
for non-critical equipment.
5. To provide and maintain adequate facilities.
6. To provide effective and trained supervision.
 Maintenance functions
• Two categories

I. Basic Functions (job-wise)

II. Composite Functions

 Basic Functions (job-wise)

• Replace: to remove an unserviceable item and install

a serviceable counterpart in its place.
• Repair: the application of maintenance services,
including fault location, removal installation and
disassembly/assembly procedures, and maintenance
actions to identify troubles and restore serviceability
to an item by correcting specific damage, fault,
malfunction, or failure in a part, subassembly,
module (component or assembly), end item or
system.
• Overhaul: that maintenance effort prescribed
to restore an item to a completely operational
condition as required by main maintenance
standard in appropriate technical publications.
• Rebuild: it consists those services necessary
for the restoration of un serviceable
equipment to a like new condition in
accordance with original manufacturing
standards.
• Service/lubricate: operations required
periodically to keep an item in proper
condition, i.e. to clean, to preserve , to drain,
to paint or to replenish fuel, lubricants,
chemical fluids, or gases.
• Inspect/check: to determine the serviceability
of an item by comparing its physical,
mechanical or electrical characteristics with
established standards through examinations.
• Test: to verify serviceability by measuring the
mechanical or electric characteristics of an item
and compare those with prescribed standards.
• Adjust: to maintain within prescribed limits, by
bringing into proper or exact position, or by
setting the operating characteristic to specified
parameters.
• Align: to adjust specified variable elements of an item
to bring about optimum or desired performance.
• Calibrate: it consists of comparisons of two
instruments, one of which is certified standard of
known accuracy, to detect and adjust any discrepancy
in the accuracy of the instrument being compared.
• Measure: the act of process of ascertaining the
extent, dimensions or quantity of something e.g.
measuring pressure or flow or heat or electrical
current with suitable instrument.
• Winding: a symmetrically laid, electrically conducting
current path in any device e.g. electrical motor /
armature winding.
• Install: the act of emplacing, seating or fixing into
position an item, part or module (component or
assembly) in a manner to allow the proper
functioning of an equipment or system etc.
 Composite Functions
• Protecting the buildings, structures and
plants/factories.
• Reducing downtimes and increasing equipment
availability: also helping in increasing equipment
utilization.
• Analyze repetitive failure and arrange their
elimination.
• Forecast maintenance spares, tool and consumables
and help their procurement and inventory
management.
• Controlling and directing labor forces.
• Maximizing utilization of available resources
• Ensuring safety of installation and reducing
environmental pollution
• Preparing maintenance budgets
• Waste reduction and waste recovery
• Improving technical communication
• Training of maintenance personnel on related jobs
 Maintenance Benefits
• Lower production unit cost
• Reduced maintenance cost and reduced lifecycle cost
• Better process stability
• Extended equipment life and lesser asset replacement
• Reduced maintenance part inventory
• Reduced overtime and reduced out-sourcing
• Improved employee safety and improved housekeeping
• Reduced risk of environmental issues
 What is Management?

• Art of doing what is possible out of what is

available
• Sharing in overheads that leads to unity of
goal
 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
• Four stages of maintenance management-
i. Design stage: Reliability and maintainability are the
important factors which must be considered in relation
to performance of equipment, capital and running
cost.
ii. Installation stage: Maintainability is an important
factor to be considered during installation. Machine
should have dynamic stability. Firstly load due to
machine tool to be transmitted uniformly to a larger
area of soil. Secondly foundation protects the machine
tool against vibrations.
iii. Commissioning stage: It is the stage of technical
performance testing, primary design faults are
located . Do the followings:
 Check the machine tool accessories for damage
 Tighten nuts on foundation
 Checking for lubrication system
 Electric connections, relays, valves etc. are checked.
iv. Operation Stage: Check points safely devices are
fitted. Foundation bolts are tightened and machine
tool should be cleaned frequently.
 Guide ways are protected from foreign materials like
chips
 Temp of the bearing should not exceed 80-90̊ C
 Lubricating points are lubricated daily
 Electric motor is protected from dust and moisture
 Check whether all levers are in position or not
 Reliability
• Reliability can be defined as the probability that a
system, component, or device will perform without
failure for a specified period of time under a given
operating conditions.
• It is an important factor in equipment maintenance
because lower equipment reliability means higher
need for maintenance.
 Definitions
• Reliability - The ability of an item to perform a
required function under stated conditions for
a stated period of time. It is usually denoted as
probability or as a success .

• Failure – The termination of ability of an item

to perform a required function.
• Observed Failure Rate – For a stated period in life of
an item, the ratio of the total number of failures in a
sample to the cumulative of the time on that sample.
The observed failure rate is associated with particular
and stated time intervals(or summation of intervals)
in the life of the item and under stated conditions.

• Observed Mean Time Between Failures(MTBF) – For

a stated period in the life of an item, the mean value
of the length of time between consecutive failures
computed as the ratio of the cumulative observed
time to the number failures under stated conditions.
• Observed mean time to failure
(MTTF)-
For a stated period in the life of an
item, the ratio of the cumulative time
for a sample to the total number of
failure in the sample during the period
under stated condition
• Mean time to repair (MTTR) is the arithmetic
mean of the time required to perform
maintenance action. MTTR is defined as the
ratio of total maintenance time and number of
maintenance action.
Name Definition

Guarantee An assurance given by the manufacturer to the vendor that the product will work without
failure for a stated period of time

Warranty A written guarantee given to the purchaser of a new appliance, automobile, or other item
by the manufacturer or dealer, usually specifying that the manufacturer will make any
repairs or replace defective parts free of charge for a stated period of time.

Maintainability The measure of the ability of an item to be retained in or restored to a specified condition
when maintenance is performed by personnel having specified skill levels, using prescribed
procedures and resources. It can be defined as the probability of that a unit will be restored
to a specified condition within a given period using specified resources.

Availability A tool for measuring the percent of time an item or system is in a state of readiness where it is
operable and can be committed to use when called upon. Availability ceases because of a
downing event that causes the item/to system become unavailable to initiate a mission when
called upon . Fraction of time the machine tool is available for production.

Availability=MTBF/(MTBF+MTTR)
Reliability The ability of an item to perform a required function under stated conditions for a
stated period of time. It is usually denoted as probability or as a success .
 Why engineering items failed?
• The design might be inherently incapable, the more
complex the design ,more the difficult to overcome
the problem
• The item might be overstressed in some way
• Failures can be caused by wear out. Sufficiently strong
at the start of the life and become weaker with age
• Failures can be caused by other time dependent
mechanism such as battery run down, creep in
turbine caused simultaneously by high temperature
and tensile stress
• Failures can be caused by sneaks . Sneak is the
condition in which the system does not work
properly even though every part does
• Failures can be caused by errors such as incorrect
specification, design ,fault assembly or test
• There are many other potential causes to failure
such as oil leaks noisy ,display flickering etc.
• Knowing ,as far as is practicable, the potential
causes of failures is fundamental to preventing
them
• Failures might be caused by variation
 What is reliability engineering
• Manufacturers often suffer high costs of failure under
warranty
• Reliability is usually concerned with failures in the time
domain. This distinction marks the difference between
traditional quality control and reliability engineering
• Whether failures occur or not and their times to
occurrence can seldom be forecast accurately .reliability
is therefore an aspect of engineering uncertainty
• Whether an item will work for a particular period is a
question which can be answered as a probability.
• Ultimately reliability engineering is effective
management of engineering
 Non-Repairable items
• Reliability is the survival probability over the items expected
life ,or for a period during its life, when only one failure can occur
• The instantaneous probability of the first and only failure is called
hazard rate
• MTTF , the expected life by which a certain percentage might have
failed is used here.
• The non repairable parts may be individual parts such as bulb,
transistor or systems comprised of many parts such as spacecraft,
microprocessor
• When a part fails in a non repairable system, the system fails,
hence the reliability is function of the time to the first part failure
 Repairable items
• Reliability is the probability that the failure will not
occur in the period of interest, when more than one
failure can occur .
• It can also be expressed as failure rate or the rate of
occurrence of failures
• Reliability is characterized by MTBF, but only under
the particular condition of a constant failure rate
• In a repairable system which contains which
contains a part type ,the part will contribute by that
amount to the system failure rate
• Maintainability: The probability that a failed item
will be restored to adequately working condition.
• Maintenance engineering: The activity of
equipment maintenance that develops concepts,
criteria, and technical requirements in
conceptional and acquisition phases to be used
and maintained in a current status during the
operating phase to assure effective maintenance
support of equipment.
• Active repair time: The component of
downtime when repair persons are active to
effect a repair.
• Mean time to repair (MTTR): A figure of merit
depending on item maintainability equal to
the mean item repair time. In the case of
exponentially distributed times to repair,
MTTR is the reciprocal of the repair rate.
• Preventive maintenance: All actions carried out
on a planned, periodic, and specific schedule to
keep an item/equipment in stated working
condition through the process of checking and
reconditioning. These actions are precautionary
steps undertaken to forestall or lower the
probability of failures or an unacceptable level
of degradation in later service, rather than
correcting them after they occur.
• Corrective maintenance: The unscheduled
maintenance or repair to return
items/equipment to a defined state and
carried out because maintenance persons or
users perceived deficiencies or failures.
• Predictive maintenance: The use of modern
measurement and signal processing methods
to accurately diagnose item/equipment
condition during operation.