ME6304 Maintenance Management (19th Batch)

 

                                                                                   

 

 

 

DEPARTMENT OF MECHANICAL AND MANUFACTURING ENGINEERING

UNIVERSITY OF RUHUNA

 

Section 1: Module Summary

 

Table 1 : Module Summary

 

Module Code

ME6304

Module Title

Maintenance Management

Credits

3.0

Total Lectures (Hr)

42

Pre-requisites

No

GPA/NGPA

GPA

Total Lab/Workshop/Field Visit/Assignments (Hr)

8

Module Aim

The aim of this module is to expose undergraduates to various types of standard plant maintenance techniques, their applications in industries and how to improve performance of a given maintenance system by applying appropriate maintenance management techniques.

Module Learning Outcomes

   After successful completion of the module, the learner should be able to

LO1:

(0.2)

Define the purpose of maintenance management, different types of maintenance techniques  and functions of the maintenance department in an industrial environment  

 

LO2:

(0.2)

Discuss what are maintenance KPIs, how analysis is done on KPIs and what are the key techniques of maintenance communication

 

LO3:

(0.4)

Describe the concepts: Autonomous Maintenance, Total Productive Maintenance (TPM), Kaizen, Non-destructive Testing (NDT) techniques, 5S and ISO quality management.

 

LO4:

(0.2)

Explain how to incorporate the maintenance management techniques to strategically improve the maintenance system of a given manufacturing plant

 

Module Outline

Introduction to Maintenance Management

Basic understanding on maintenance management; activities of a maintenance department of a plant;  organizational structures involved; 

 

Overview of Different Plant Maintenance Techniques

Planned maintenance techniques: Preventive maintenance techniques (time based, usage based, condition based); preventive maintenance machine manual; pre and post evaluation of preventive maintenance activities; Conditioning monitoring;  Machine health check; Corrective maintenance; Shutdown maintenance;

Unplanned maintenance techniques: Breakdown maintenance; Opportunistic maintenance;

 

 

 

Key Performance Indicators (KPIs) used in Maintenance Management

Overall Equipment Effectiveness (OEE)-1; OEE-2; Mean time between failures (MTBF); Mean time to repair (MTTR); Maintenance cost; Percentage of effective time within a breakdown or a preventive maintenance activity; Cumulative breakdown time; Other KPIs;

 

Standard Analysis Techniques used in Maintenance Management

Introduction to “analysis to insight approach”; Bad actor analysis; Failure mode and effect analysis (FMEA); Root cause analysis (2-WHY analysis, Cause and Effect analysis OR Prato analysis); Wrench analysis; 2-by-2 prioritisation of actions; Plan-do-check-act (PDCA) method;

 

Maintenance Communication Systems

Purpose of maintenance communication; documentation (breakdown recording, PM pre-evaluation and  post-evaluation, material requisition, work permits, job ordering, approvals of dispatch (AODs); Tags; Display boards; Kanban systems; verbal communication means;

 

Introduction to Autonomous Maintenance

The concept of Autonomous Maintenance; Objectives of Autonomous maintenance; implementation levels;

 

Introduction to Total Productive Maintenance (TPM)

The concept of TPM, Goals of TMP; 5 pillars of TPM, Sri Lankan success stories of TPM; Implementation of TPM; Function of the Japan institute of plant maintenance (JIPM); TPM awards;

 

Strategies to Implement Maintenance Improvements in a Plant

Initial agreement; Pre-awareness; Plant diagnosis; Prioritisation and planning of implementations; Implementation; Progress review;

 

Introduction to KAIZENs

Difference between idea generation and Kaizen; Evaluation of Kaizen; Rewarding; Rules involved; Documentation;

 

Non-Destructive Testing (NDT) Techniques used in Plant Maintenance

Different types of NDT testing techniques: Liquid penetrate; Visual; Ultrasonic; X-ray; Thermography; Acoustic Emission; Eddy Current; Other techniques; Equipment involved;

 

Introduction to the 5S Concept

Purpose of 5S; 5S frame work: Sort (SEIRI), Systemise (SEITON), Cleaning (SEISO), Standardise (SEIKETSU), Sustain (SHITSUKE), Evaluation of 5S implementation success;

 

Introduction to ISO Quality Management Systems

Importance of ISO standardisation; Background of ISO standards; Different types of ISO standards;

 

Marks Allocation

 

·         Continuous Assessment                                    40%

a.       Individual assignment 1 (10)                             [10%]

b.       Individual assignment 2 (10)                               [10%]

c.       Individual assignment-3/Field visit report (10)   [10%]

d.       Group Assignment (10)                                       [10%]   

·         End Semester Evaluation                                   60%

a.       Written examination                                                [60%]

Eligibility to Appear for the End Semester Evaluations

·         Minimum of 80% attendance for theory classes

·         Completion of all laboratory session(s)/field session(s)/design session(s)/work camp(s)/project(s)

 

Necessary Conditions to pass the Module

·         Achieve at least 50% of marks for the continuous assessments

·         Achieve at least an overall mark of 40% with a minimum of 30% in end semester evaluation

 

Recommended Reading
  • Engineering Maintenance: a modern approach by Dhillon, B.S., CRC Press.
  • Industrial maintenance management: by Srivastava, Sushil Kumar, New Delhi: S. Chand.
  • Practical plant failure analysis: a guide to understanding machinery deterioration and improving equipment reliability by Sachs, Nevile W, CRC Press.
  • Reliability-centred maintenance: by Moubray, John, Oxford: Butterworth.
  • Industrial engineering and production management: by Tompkins Telsang, Martand, New Delhi: S. Chand.