A Course Material on Maintenance Engineering By Mr. E.R.SIVAKUMAR.M.E,(Ph.D), HEAD & ASSOCIATE PROFESSOR DEPARTMENT OF MECHANICAL ENGINEERING SASURIE COLLEGE OF ENGINEERING VIJAYAMANGALAM – 638 056 QUALITY CERTIFICATE This is to certify that the e-course material Subject Code : ME2037 Scubject : Maintenance Engineering Class : IV Year being prepared by me and it meets the knowledge requirement of the university curriculum. Signature of the Author Name: Mr.E.R.SIVAKUMAR.M.E,(Ph.D) Designation: This is to certify that the course material being prepared by Mr.E.R.Sivakumar M.E,(Ph.D) is of adequate quality. He has referred more than five books among them minimum one is from abroad author. Signature of HD Name:Mr.E.R.SIVAKUMAR.M.E,(Ph.D), SEAL CONTENTS SL. PAGE TOPICS NO. NO. SYLLABUS UNIT – I PRINCIPLES AND PRACTICES OF MAINTENANCE PLANNING 1.1 Maintenance Engineering 1 1.1.1.Introduction 1 1.1.2. Maintenance Manager 2 1.1.3.Maintenance Engineering Jobs 2 1.1.4.Definition of Maintenance 2 1.1.5.Purpose of Maintenance 2 1.1.6.Principle Objectives in Maintenance 2 1.1.7.Problems in Maintenance 2 1.2 Basic Principles of maintenance planning 3 1.2.1.Maintenance Planning 3 1.2.2. Planning Objectives 3 1.2.3. Planning Procedures 3 1.2.4.Basic Levels of Planning Process (Depend on The Planning 4 Horizon) 1.2.4.1.Long Range Planning 4 1.2.4.2. Medium-Range Planning 4 1.2.4.3. Short-Range Planning 4 1.3 Objectives and Principles of Planned Maintenance Activity 4 1.4 Importance and benefits of sound Maintenance systems 5 1.5 1.5.1.Maintenance organization 5 1.5.2.Maintenance Organization Objectives and Responsibility 5 1.5.3.Determinants of a Maintenance Organization 6 1.5.4.Maintenance Capacity Planning 6 1.5.5. Centralization vs Decentralization 6 1.5.6 In-house vs Outsourcing 7 7 1.5.7.Design of the Maintenance Organization 7 1.5.8 Current Criteria for Organizational Change 8 1.5.9 Criteria to Assess Organizational Effectiveness 8 1.5.10. Basic Types of Organizational Models 9 1.5.11.Material and Spare Parts Management 12 1.5.12. Establishment of Authority and Reporting 12 1.5.13. Quality of Leadership and Supervision 12 1.5.14. Incentives 12 1.5.15. Education and Training 12 1.5.16. Management and Labor Relations 13 1.5.17. Summary 13 1.6 Maintenance economics 13 1.7 Reliability 17 UNIT II MAINTENANCE POLICIES – PREVENTIVE MAINTENANCE 2.1 Maintenance Catagories 22 2.2 Total Productive Maintenance 23 2.3 Stakeholders 25 2.4 Maintenance Scheduling 32 2.5 Elements of Sound Scheduling 34 2.6 Maintenance Job Priority System 35 2.7 Scheduling Techniques 35 2.7.1 Gantt Charts and Scheduling Theory 36 2.7.2 Project Scheduling 39 2.7.3 Critical Path Method 43 2.7.4 Program Evaluation Review Techniques (PERT) 45 2.8 Scheduling Using Computers 47 2.9 Summary 47 2.10 Lubrication 48 UNIT III CONDITION MONITORING 3.1 Condition Monitoring 52 3.2 Methods Of Cm 53 3.3 Benefits 54 3.4 Load Testing 55 3.5 Types of Condition Monitoring Systems 55 3.6 Establishing a Condition Monitoring Program 57 3.7 Condition Monitoring Of Machinery 58 3.8 Principles and Methods 61 3.9 Vibration Monitoring System (VMS) Specification 63 3.10 Thermistors 64 3.11 Wear Debris Analysis 75 UNIT IV REPAIR METHODS FOR BASIC MACHINE ELEMENTS 4.1 Repair Methods For Beds 76 4.2 Repair methods for slideways 88 4.3 FMEA - Failure Modes and Effects Analysis 96 4.4 Gears 98 4.5 Bearings 111 4.6 Factors Influencing the Performance of Ball and Rolling Bearing 116 UNIT V REPAIR METHODS FOR MATERIAL HANDLING EQUIPMENT 5.1 Material-handling equipment 141 5.2 Maintenance Strategies for Overhead Cranes and Lifting Equipment 142 5.3 A systems approach for maintenance and renewal efficiency 145 5.4 The Computerized Maintenance Management System (CMMS) 147 5.5 Work Order System 157 QUESTION BANK 160 UNIVERSITY QUESTION PAPERS 204 ME1012 – MAINTENANCE ENGINEERING L T P C 3 0 0 3 UNIT I PRINCIPLES AND PRACTICES OF MAINTENANCE PLANNING 10 Basic principles of maintenance planning – Objectives and principles of planned maintenance activity – Importance and benefits of sound maintenance systems – Reliability and machine availability – MTBF, MTTR and MWT – Factors of availability – Maintenance organization – Maintenance economics. UNIT II MAINTENANCE POLICIES – PREVENTIVE MAINTENANCE 9 Maintenance categories – Comparative merits of each category – Preventive maintenance, maintenance schedules and repair cycle – Principles and methods of lubrication – TPM. UNIT III CONDITION MONITORING 9 Condition monitoring – Cost comparison with and without CM – On-load testing and off-load testing – Methods and instruments for CM – Temperature sensitive tapes – Pistol thermometers – Wear-debris analysis. UNIT IV REPAIR METHODS FOR BASIC MACHINE ELEMENTS 10 Repair methods for beds, slide-ways, spindles, gears, lead screws and bearings – Failure analysis – Failures and their development – Logical fault location methods – Sequential fault location. UNIT V REPAIR METHODS FOR MATERIAL HANDLING EQUIPMENT 8 Repair methods for material handling equipment – Equipment records – Job order systems –Use of computers in maintenance. Total: 45 TEXT BOOKS 1. Srivastava, S.K., “Industrial Maintenance Management”, S. Chand and Co., 1981. 2. Bhattacharya, S.N., “Installation, Servicing and Maintenance”, S. Chand and Co., 1995. REFERENCES 1. Garg, M.R., “Industrial Maintenance”, S. Chand and Co., 1986. 2. Higgins, L.R., “Maintenance Engineering Handbook”, 5th Edition, McGraw Hill, 1988. 3. Davies, “Handbook of Condition Monitoring”, Chapman and Hall, 1996. ME2037 Maintenance Engineering UNIT-1 PRINCIPLES AND PRACTICES OF MAINTENANCE PLANNING 1.1.Maintenance Engineering 1.1.1.Introduction Maintenance Engineering is the discipline and profession of applying engineering concepts to the optimization of equipment, procedures, and departmental budgets to achieve better maintainability, reliability, and availability of equipment. Maintenance engineering is the occupation that uses engineering theories and practices to plan and implement routine maintenance of equipment and machinery. This must be done in conjunction with optimizing operating procedures and budgets to attain and sustain the highest levels of reliability and profit. Maintenance engineers are often required to have knowledge of many types of equipment and machinery. A person working in the field of maintenance engineering must have in-depth knowledge of or experience in basic equipment operation, logistics, probability, and statistics. Experience in the operation and maintenance of machinery specific to a company's particular business is also frequently required. Since the position normally requires oral and written communications with various levels of personnel, excellent interpersonal communication and participatory management skills are also desirable. Maintenance engineering positions require planning and implementing routine and preventive maintenance programs. In addition, regular monitoring of equipment is required to visually detect faults and impending equipment or production failures before they occur. These positions may also require observing and overseeing repairs and maintenance performed by outside vendors and contractors. In a production or manufacturing environment, good maintenance engineering is necessary for smooth and safe daily plant operations. Maintenance engineers not only monitor the existing systems and equipment, they also recommend improved systems and help decide when systems are outdated and in need of replacement. Such a position often involves exchanging ideas and information with other maintenance engineers, production managers, and manufacturing systems engineers. Maintenance engineering not only requires engineers to monitor large production machine operations and heavy duty equipment, but also often requires involvement with computer operations. Maintenance engineers may have to deal with everything from PCs, routers, servers, and software to more complex issues like local and off-site networks, configuration systems, end user support, and scheduled upgrades. Supervision of technical personnel may also be required. Good maintenance engineering is vital to the success of any manufacturing or processing operation, regardless of size. The maintenance engineer is responsible for the efficiency of daily operations and for discovering and solving any operational problems in the plant. A company's success may depend on a quality maintenance engineering department that can be depended upon to discover systematic flaws and recommend solid, practical solutions. SCE 1 Department of Mechanical Engineering ME2037 Maintenance Engineering 1.1.2. Maintenance Manager If you choose to take an entry-level position in order to become a facilities maintenancemanager, you can expect to spend several years working maintenance positions as you learn the skills necessary to become a manager. Larger employers with greater maintenance needs generally look for a facilities maintenancemanager who can perform these tasks when needed, but is more focused on managing an in-house staff responsible for the majority of the actual work. 1.1.3.Maintenance Engineering Jobs Typically, maintenance engineers need to possess knowledge of the principles of building or mechanical engineering. Maintenance engineer jobs generally require the person to maintain the plant or manage a crew who maintains it. They also set schedules, hand out paychecks, assign job duties, and monitor daily progress. Most construction engineeringjobs require at least a bachelor's