A Research Paper On

“Trend in Maintenance Management”

By

Er. Utkarsh Amaravat

(Anand Institute of Management, Anand)

To be presented at the National Conference On 4th

February, 2013 On “Trend and opportunities in Management

Discipline”

Organized by,

Anand Institute of Management, Anand

Affiliated to Gujarat Technological University

Abstract

In today’s competitive world its necessary any industry run their operation in smooth manner and deliver its

customer best products at minimum time, and to fulfil this purpose maintenance management is key area

where every industry work. Now a day’s continuous or mass production system is used in industry in which

if any one of the equipment is fail remaining all work schedule are disturbed, in this type of scenario

maintenance management important increase automatically. Maintenance management is not a new concept

but oldest in nature which passes so many phases of it journey. This paper derives various trend or concept

used in maintenance management to maintain equipment in running condition and also achieving optimum

level of productivity.

Maintenance Management

The old concept of Maintenance was “Maintenance is about preserving physical asset”. However, the new

concept is that “Maintenance is about preserving the functions of assets”. Maintenance can be define as “It is

a routine or a recurring process of keeping a particular machine or asset in its normal operating condition, so

that it can deliver its expected performance or service without causing any loss of time on account of

accidental damage or breakdown.”

Main function is to keep the equipment in working condition by replacing or repairing some of the

component of the machine and increased availability of production system, with increased safety and

optimized cost.

Maintenance management involve managing function of maintenance. Maintaining equipment in the field

has been a challenging task since the beginning of industrial revolution. Since then, a significant of progress

has been made to maintain equipment effectively in the field. As the engineering equipment becomes

sophisticated and expensive to produce and maintain, maintenance management has face even more

challenging situations to maintain effectively such equipments in industrial environment.

Maintenance Management is important aspect because,

1. It lowers down production unit cost

2. It minimize downtime

3. It improves total availability of system.

4. It extended useful life of equipment

5. It increases safety of personals.

6. It helps in reducing overtime and out-sourcing.

7. It provides better process stability.

8. It reduce maintenance part inventory.

Literature Review

1. Uysal F and Tosun O (2012) studied on Fuzzy Topics-based computerized maintenance management

system selection.

The researchers find out that to compare CMMS applications actual capabilities in order to select the

right one, rather than considering only their purchase cost.

2. Coopoosamy K (2011) studied on an integrated maintenance management system model for the

pharmaceutical industry.

The researcher find out that the integrated maintenance management model can be implemented within

the company.

3. Kumar S, Khan L A and Gandhi O P (2011) review on a kaleidoscopic view of psychology in design for

maintainability of mechanical system.

The researchers discuss in research paper about new shift in engineering design, in general and design

for maintainability (DFM) of mechanical systems.

4. Pophaley M and Vyas R K (2010) studied on plant maintenance management practices in automobile

industries: A retrospective and literature review.

The researchers find out that research work on plant maintenance management practices in automobile

industries under the traditional operation paradigm.

5. Lateef O A, Khamidi M F and Idrus A (2010) studied on building maintenance management in

Malaysian university campuses.

The researcher find out that building maintenance management associated services and the upkeep of the

building performance.

6. Gandhi O P (2007) review on maintenance management.

The researcher discusses in research paper about various aspects of maintenance management and

concluded to meet challenges.

7. Garg A and Deshmukh S G (2006) review on maintenance management – literature review and

directions.

The researcher find out that maintenance management range from various optimization models,

maintenance techniques, scheduling and information system etc.

8. Kans M (2006) review on computerized maintenance management support

The researcher discuss in research paper that maintenance management information system has change

in aspects- technology, function and strategy.

Trend in Maintenance Management

Actually, Maintenance is an age old function, which developed and progressed, knowingly or unknowingly,

along with the operation of the equipment/ machines. In early ages, maintenance was not a separate identity

but the job of maintenance was considered as part and parcel of operator’s job. This was possible because of

simplicity and openness of the machines. Even carvings on the Egyptian tomb “Ra-Em-Ka-“(about 2600 –

1700 BC) used lubrication to transport a stone mountain. Here some concept of Maintenance management

given as per there generation.

Before 1950,

1. Breakdown Maintenance Management System

Breakdown Maintenance concept/system is oldest concept in Maintenance management. In this not do

anything as long as everything is going well and maintenance repair is done after failure has already

occurred. The equipment allowed running undisturbed till it fails. This maintenance concept also called as

Reactive Maintenance Concept or Unplanned Maintenance or Operate to failure concept.

Breakdown maintenance can only be suitable for small scale industries where numbers of equipments are

few and sudden failure of equipment will not cause several financial losses in term of delivery commitment.

This system look to be simple and less expensive, but is not really so. It does not provide any guarantee of

reliability to the smooth production running. In breakdown maintenance downtime of equipment is high

after breakdown.

Between 1950 to 1960,

2. Preventive Maintenance Management System

Some group of Japanese engineers started a new concept/system in maintenance that consisted on following

the manufactures recommendation about the care that should be taken in the operation and maintenance of

machine and devices. That new concept was called Preventive Maintenance or Schedule Maintenance

Concept. This Maintenance program is scheduled in consultation with the production/operation department

so that relevant equipment is made available for maintenance work and utilizes idle time of equipment. In

this maintenance action such as inspection, lubrication, cleaning, adjustment and replacement are undertaken

at fixed interval of number of hours or kilometres. Although it reduces downtime it was an expensive

alternative. The reason many parts were replaced on a time basis, while they could have lasted longer. Also

many unnecessary man-hours were put into it and in not few cases excess lubrication caused more damage

than good.

Between 1960 to 1970,

3. Predictive Maintenance Management System

With time change new concept/system established which determined a more professional approach. This

assign of higher responsibility to all the people related to maintenance consisted of series of considerations

about the reliability and design of equipment and plant itself. When equipment/system is taken down for

maintenance, changing one or few warn out component opportunity can be utilized for maintenance,

changing other wearing out component even though they have not failed. This would probably be

economical in the long run. It is very beneficial for non-monitored component which are inaccessible for

inspection. This maintenance concept also called as Productive Maintenance Concept or Opportunity

Maintenance Concept or Reliability Maintenance Management Concept.

4. Condition based Maintenance Management System

Condition monitoring detects and diagnoses faults and it helps in planned maintenance based on equipment

condition. This condition based on maintenance strategy is preferred for critical system and for such system

breakdown maintenance is to be avoided. A number of condition based maintenance techniques such as

vibration, temperature, oil analysis, etc. Have been developed, which guide the users in planned

maintenance.

Between 1970 to 1985,

5. Total Productive Maintenance Management System

The globalization of the market created new stronger needs for excellence in all activities. The world class

standards in terms of equipment maintenance were understood, a dynamic system was created. Total

Productive Maintenance is a continuous improvement concept that has proven to be effective, first in Japan

and now back in America (where first created). It is about the involvement and participation of each and

every one of the members in the organizations toward optimizing the outcome of each piece of equipment.

This is a completely new philosophy is different approach that will keep updated by itself. It implies a

continuous improvement in all aspect and is also called Total Participation Maintenance.

The purpose is to transform the attitude of all the members of the industrial community, all kinds and levels

of workers, operators, supervisors, engineers, administrators are included in this major responsibility. TPM

implementation is a goal that all company members share. It also generates benefits for all. Through this

effort, all are responsible for the up keeping of the equipment. It becomes more productive, safer and easier

to operate and even looks nicer. The participation of people, who are not familiar with the equipment and its

operation, enriches the result because their observations are in many cases more objective than those of the

people who live with equipment in a daily basis.

6. Routine Maintenance Management System

It is the Simplest form of part maintenance but very essential which Carrying out minor maintenance job

such as cleaning, lubrication, inspection, minor adjustment of pressure, flow, tightness, etc. or inspection of

bearing, belts, coupling, joints, foundations, bolts, earthings, etc. at regular intervals. Small/Critical effects

using such inspection are rectified immediately. It is not need base, all equipment are inspected. It may

consider small portion of preventive maintenance. It needs very little investment in terms of time and

money. The duration routine maintenance is generally so small that it does not affect the output of machine

appreciably. However, the cost of not doing routine maintenance may be very high as a small develop in

big and catastrophic failure.

After 1985,

7. Computerized Maintenance Management System (CMMS)

It is also known as Enterprise Asset Management and Computerized Maintenance Management Information

System (CMMIS). A CMMS software package maintains a computer database of information about an

organization’s maintenance operations. This information is intended to help maintenance worker do their

jobs more effectively and to help management make informed decisions. CMMS data may also be used to

verify regulatory compliance. CMMS package may be used by any organization that must perform

maintenance on equipment, assets and property. CMMS packages can produce status reports and documents

giving details or summaries of maintenance activities. The more sophisticated the package, the more

analysis facilities are available. Many CMMS packages can be either web based meaning they are hosted by

the company selling the product on an outside server or LAN based meaning that the company buying the

software hosts the product on their own server.

Selection criteria for selection of good Maintenance Management System

Presently many maintenance management systems are in use in industries and selection has to be made

depending the need, complexity and reliability needed and also considering techno-economics. Criteria must

consider are-

1) Work Procedures (Maintenance and Operation etc.)

2) Problems, Defect and Fault Reports

3) Work Schedules, Job Orders etc.

4) Work History

5) Assets

6) Inventory

7) Finance, etc.

Conclusion

All above discussion has briefly focused on the various trend of maintenance management. In maintenance

new trend come out but old trend not closed or go out because all maintenance management system has their

own applicability. Maintenance management plays larger role in years to follow as industrial growth

increase worldwide and increase competition and automation of plants. As industrial progress increases the

downtime cost for system is increase and to meet these challenges, maintenance person has to use latest

technology and develop management skill to perform effective role in industrial profit.

Bibliography

1. Srivastva, S.K. (2012), Industrial Maintenance Management, S. Chand and Co., Fifth addition.

2. Uysal, F. and Tosun, O. (2012), “Fuzzy Topics-based computerized maintenance management system

selection”, available at <http://www.emeraldinsight.com/journals.htm?articleid=17014448&show=html>

Accessed in 2012.

3. Coopoosamy, K. (2011), “An integrated maintenance management system model for the pharmaceutical

industry”, available at

<http://dspace.nmmu.ac.za:8080/jspui/bitstream/10948/1583/1/K%20Coopoosamy%20rev4%20(2).pdf>

Accessed in 2011.

4. Kumar, S., Khan, L.A. and Gandhi, O.P. (2011), “A kaleidoscopic view of psychology in design for

maintainability of mechanical system”, available at

<http://www.emeraldinsight.com/journals.htm/journals.htm?issn=1726-

0531&volume=9&issue=3&articleid=1954531&show=pdf> Accessed in 2011.

5. Pophaley, M. and Vyas, R.K. (2010), “Plant maintenance management practices in automobile

industries: A retrospective and literature review”, available at

<http://upcommons.upc.edu/revistes/bitstream/2099/9948/1/pophaley.pdf> Assessed in 2010.

6. Lateef, O.A., Khamidi, M.F. and Idrus, A. (2010), “Building maintenance management in Malaysian

university campuses”, available at

<http://epress.lib.uts.edu.au/journals/index.php/AJCEB/articles/download/1593/1738> Assessed in 2010.

7. Gandhi, O.P. (2007), “Maintenance management”, available at

<http://www.iitr.ac.in/outreach/web/CIRCIS/sps2007/Maintenance%20Management.doc> Accessed in

2007.

8. Garg, A. and Deshmukh, S.G. (2006), “Maintenance management – literature review and directions”,

available at <www.emeraldinsight.com/journals.htm?articleid=1567067&show=html> Accessed in

2006.

9. Kans, M. (2006), “Computerized maintenance management support” available at

<http://citeseerx.ist.psu.edu/viewdoc/download?doi=10.1.1.104.7042&rep=rep1&type=pdf> Accessed

in 2006.

10. Higgins, L.R. (1995), Maintenance Engineering Handbook, McGraw Hill, fifth addition.