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    What Are the Objectives & Functions of Maintenance Management?

    The function of maintenance management is really important & maintenance is an activity that …

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    May 12, 2021

    What Are the Objectives & Functions of Maintenance Management?

    One must understand the role of maintenance. Maintenance is not only done for repairing assets but also assists in prolonging the asset's life.

    Nowadays organizations and management starting to understand the power of maintenance. According to Statista,  “It is projected that the revenue of repair and maintenance in the U.S. will amount to approximately 191,4 billion U.S. Dollars by 2024.”

    In maintenance management, several objectives are settled, such as improving performance, giving regular maintenance, and replacing certain parts of the machine.

    So that, machines can perform better and productivity can be increased and availability & reliability as well. We have discussed the objective of maintenance management & functions of maintenance management below in detail!

    What Are the Objectives of Maintenance Management?

    The objectives of maintenance management are as follow:

    1. Making Assets Reliable

    Assets maintained are more reliable rather than unmaintained assets everybody knows it. If assets are given maintenance on time their performance improves. Maintenance is very important it ensures that assets are well-maintained and their performance can be boosted with calibration & adjustment.

    2. Minimizing Maintenance Cost

    Maintenance cost has always been an issue for organizations! When assets are not maintained chances of breakdown are increased. It results in expensive maintenance as lots of activities need to be done including changing the part which is not working. Furthermore, the maintenance team tries to bring the asset into running condition as soon as possible.

    3. Decreasing Downtime and Minimizing Failure

    Upkeep groups endeavor to amplify gear accessibility, and they are better ready to do so when preventive support occupations are overseen well. Maintenance professionals should have the option to keep steady over preventive upkeep to keep machines running so failures are minimized. So, when machines do require fixes, they should be done rapidly and productively.

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    4. Enhance Productivity Level

    When work is done properly such as maintenance tasks are prioritized and issues are resolved quickly, the machine works for several hours without any issue. In that way the quality of work is more efficient, more productive, and when productive work is delivered return on investment increases. It also means that the bottom line is improved as well.

    5. Comply with Rules & Regulations

    It does not matter in which industry your business belongs to because rules & regulations are there for all business types. If your business assets are not maintained, it might risk your employees' lives and the environment will be not good.

    Furthermore, if found that your assets are not maintained then your organization will end up paying penalties. But if assets are maintained your organization will face no issues of compliance or rules & regulations.

    Also Read: Difference Between Downtime & Breakdown Time in Terms of Maintenance

    What Are the Functions of Maintenance Management?

    The functions of maintenance management are as follow:

    Policies, rules, and regulations must be developed to make maintenance work more efficient and more effective.

    The procedure of maintenance operation shall be done on time so that maintenance work is not delayed.

    Ensure that organization complies as per the rules, regulations, and policies.

    Ensure maintenance is effective and cost-efficient as well.

    One of the main functions of maintenance management is to make sure that facility parts such as elevators, escalators, sewers, electric store, HVAC (Heating ventilation air condition) work fine.

    Document all the maintenance activities that are done on each day including their expenses. Documentation can help in keeping track of maintenance work.

    To deliver effective maintenance work, the maintenance team needs inventories. Therefore, maintenance management needs to ensure that inventory is available for the maintenance team.

    Forecasting demands and planning for maintenance expenditure are also significant.

    Keeping track of assets, equipment, and machines so that they are secured from theft. Theft is a big problem in all organizations, especially small equipment. Therefore, it is the duty of management so that their machines and assets are protected.

    The most important above all is to make sure that equipment is not neglected and provided maintenance on time.

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    Reliabilityweb The Maintenance Function

    Reliability Web

    The Maintenance Function

    In Webster's dictionary it defines maintenance as:

    MaintenanceTo maintainKeep in existing conditionPreserve, protectKeep from failure or decline

    The ultimate goal of maintenance is to provide optimal reliability which meets the business needs of the company. Many people do not know the definition of reliability and it is:

    "The probability or duration of failure-free performance under stated conditions"

    Now that we understand maintenance maintains reliability let's see how a proactive maintenance process works. John Day, one the most well known proactive maintenance management advocates who was formerly the maintenance and engineering manager for Alumax Mt Holly was my mentor and manager for a number of years. John has spoken all over the world as to his model of proactive maintenance. I wanted to provide a valuable insight into what a successful plant considered the definition of the word "Maintenance" to be and in which I align with very much as it relates to the maintenance process.

    John Day titled his vision and process to maintenance as:STRATEGY TO ACHIEVE WORLD-CLASS PRODUCTION THROUGH RELIABILITYINTRODUCTION

    Alumax of South Carolina is an aluminum smelter that produces in excess of 180,000 MT of primary aluminum each year. It began operation in 1980 after a 2-year construction phase. The plant is the last greenfield aluminum smelter constructed in the U.S. Alumax of SC is a part of Alumax, Inc., which has headquarters in Norcross, Georgia; a suburb of Atlanta, Georgia. Alumax, Inc. is the third largest producer of primary aluminum in the U.S. and the fourth largest in North America.

    The vision of general management was that the new smelter located on the Mt. Holly Plantation near Charleston, SC, would begin operations with a planned maintenance system that could be developed into a total proactive system. At the time in 1978-79, there were no maintenance computer systems available on the market with the capability to support and accomplish the desired objectives. Thus TSW of Atlanta, Georgia was brought on site to take not only the Alumax of S.C. maintenance concepts and develop a computer system, but they were to integrate all the plant business functions into one on-line common data base system available to all employees in their normal performance of duties.

    Since the development and initial operation of the Alumax of SC maintenance management system, it has matured and rendered impressive results. These results have received extensive recognition on a national and international level. The first major recognition came in 1984 when Plant Engineering magazine published a feature article about the system. Then in 1987 A.T. Kearney, an international management consultant headquartered in Chicago, performed a study to find the best maintenance operations in North America. Alumax of S.C. was selected as one of the seven "Best of the Best". And in 1989, Maintenance Technology magazine recognized Alumax of SC as the best maintenance operation in the U.S. within its category and also as the best overall maintenance operation in any category. Mt Holly's proactive model is shown below in figure 1.

    MAINTENANCE APPROACHES

    From a basic point of view there are two maintenance approaches. One approach is reactive and the other is proactive. In practice there are many combinations of the basic approaches.

    The reactive system (see Figure 1.1.1) responds to a work request or identified need, usually production identified, and depends on rapid response measures if effective. The goals of this approach are to reduce response time to a minimum (the computer helps) and to reduce equipment down time to an acceptable level. This is the approach used by most operations today. It may well incorporate what is termed as a preventative maintenance program and may use proactive technologies.

    Figure 1.1.1. Reactive Maintenance Model

    The proactive approach (see figure 1.1.2) responds primarily to equipment assessment and predictive procedures. The overwhelming majority of corrective, preventative, and modification work is generated internally in the maintenance function as a result of inspections and predictive procedures. The goals of this method are continuous equipment performance to established specifications, maintenance of productive capacity, and continuous improvement. Alumax of SC practices the proactive method. The comments which follow are based upon the experience and results of pursuing this vision of maintenance.

    Figure 1.1.2. Mt Holly's Proactive Maintenance Model

    MAINTENANCE MANAGEMENT PHILOSOPHY

    Alumax of SC began development of the maintenance management concept with the idea that maintenance would be planned and managed in a way that provides an efficient continuous operating facility at all times. Add to this that maintenance would also be treated as an investment rather than a cost, and you have the comprehensive philosophy on which the maintenance management system was built. An investment is expected to show a positive return, and so should maintenance be expected to improve the profitability of an operation. The management philosophy for maintenance is just as important as the philosophy established for any business operation. For most industries, maintenance is a supervised function at best, with little real cost control. But it must be a managed function employing the best methods and systems available to produce profitable results that have a positive effect on profitability.

    स्रोत : reliabilityweb.com

    What is Repair and Maintenance?

    Learn more about repair and maintenance. Including what’s the difference between repair and maintenance, different types, and how to use repair and maintenance.

    Repair and maintenance

    Plan, track, and measure maintenance — for free using Fiix

    No matter which industry you are in, if you work in maintenance, the goal is the same-to keep facility equipment, tools, and infrastructure in good shape and performing efficiently, and avoid unplanned downtime or equipment failure. Repair and maintenance enables us to achieve this.

    What is the difference between repair and maintenance?

    Repair and maintenance are used hand-in-hand, but they refer to different things in the asset management space. Repairs are restoration work for when an asset breaks, gets damaged, or stops working. Maintenance refers to routine activities and/or corrective or preventive repair done on assets to prevent damage and prolong the life expectancy. Examples include regular cleaning of air-conditioning units, grease traps, repainting, and routine inspections.

    Levels of repair

    The level of repair needed to be performed on an asset depends on the level of failure causing the asset’s malfunction. There are two basic types of equipment failure.

    Partial failure

    The asset still functions, but at a lower capacity. There are also potential safety hazards. Corrective actions can get the asset back to good health and full functionality before the identified issue leads to complete failure.

    Complete failure

    The asset has completely malfunctioned and can’t be used until it is repaired. The amount of resources needed to fix the issue will depend on the root cause of the failure.

    Equipment breakdowns can be very expensive, both in terms of fixing the issue and causing a delay or stoppage in production. Some failures are due to human error, unforeseen accidents, or the natural wear and tear of assets that happens over many years of use. With preventive maintenance, many of these situations can be avoided.

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    Types of maintenance

    Maintenance covers all maintenance work performed on assets. Examples of maintenance activities include visual inspections, functional checks, spare parts replacements, and installing a new asset in a facility.

    There are many different maintenance strategies that you can mix and match, depending on your assets, industry, and the size and experience of your maintenance team. The four most common types of maintenance strategies are:

    Reactive maintenance

    Also known as breakdown or run-to-failure, reactive maintenance is when assets get fixed as they break. Since repairs are not planned, it’s a good method to employ for equipment that is not essential for operations or has a low cost.

    While it requires minimal planning, the drawbacks of reactive maintenance can be substantial if it’s not carried out correctly. If the approach is used for all equipment, there can be huge delays in production when a critical piece of equipment fails. If you don’t have the right parts and supplies on hand, the costs for rushed shipping can become significant. In short, reactive maintenance often means more downtime and higher maintenance costs when it’s not used strategically.

    Preventive maintenance

    Also known as proactive maintenance, this method involves taking assets offline and inspecting or repairing them at predetermined intervals (usually time or event-based triggers). This approach aims to extend the useful life of an asset and prevent breakdowns from occurring. Many organizations conducting preventive maintenance use CMMS software to trigger work orders when a PM is due. This allows a facility to automate the majority of its scheduling. Because planning is done in advance, it’s much easier to have the right parts and resources on hand to complete each task.

    Predictive maintenance

    Predictive maintenance aims to predict failures before they happen so maintenance can occur at just the right time. It uses data from machine sensors and smart technology to alert the maintenance team when a piece of equipment is at risk of failing. For example, a sensor may use vibration analysis to alert the maintenance team that a piece of equipment is at risk of failing.

    Visual inspections of equipment can be done, but the easiest way to establish a predictive maintenance strategy is by using a CMMS to track meter readings. Data and sensor information means maintenance is determined by the actual condition of equipment, rather than a best-guess schedule or gut feel.

    Reliability-centered maintenance

    Reliability-centered maintenance addresses the fact that failure is not always linear. This type of maintenance involves analyzing all the possible failure modes for each piece of equipment and creating a customized maintenance plan for each individual machine. The ultimate goal of RCM is to increase equipment availability or reliability.

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