Maintenance Engineering Handbook

MAINTENANCE ENGINEERING

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.

PRINCIPLES AND PRACTICES OF MAINTENANCE PLANNING

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 require

 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.

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