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DRIVE SPRING 2016
PROGRAM MBA
SEMESTER IV
SUBJECT CODE & NAME OM 0015 – MAINTENANCE MANAGEMENT
1
Write short notes on the following:
a.
Proactive Maintenance
b.
Planned Maintenance Work Cycle
c.
Maintenance organising schedule
d.
Areas of Maintenance Practices
Answer: a) During the production
process, there are usual wear and tear of machines and equipment. If this wear
and tear is not addressed on time, it may lead to decreased productivity,
obstructions in the production process, delays in product delivery, and so on.
Organisations take various
2
What do you mean by Asset Strategy? Explain briefly Steps Involved in
Developing an Asset Strategy.
Asset Strategy
Steps of
developing an asset strategy
Answer: A strategy is a plan that is created by organisations to
achieve a specific target. In simple words, it can be defined as a route map
that involves a number of steps, actions, standards, plans, and policies
required to attain the future goals of an organisation. On the other hand, an
3
Assume you are the head of the maintenance department in a manufacturing
organisation. You are assigned a responsibility of implementing a maintenance
improvement program. What components would you include in the maintenance
improvement program?
Maintenance
improvement program
Components
Answer: The main aim
of every organisation is to achieve long-term success. For this, organisations
establish certain goals and objectives arrange adequate resources, carry out
processes with the help of appropriate methods and techniques. However, no
organisation can remain static to a single goal, process, or technique for a
long time. With constant development in the
4
What do you mean by Machine Quality? Which Aspects are to be Considered for
Machine Quality?
Machine Quality
Aspects to be
considered
Answer: Machine
quality can be defined as the ability of a machine or equipment to produce
products that conform to defined specifications and are free of defects,
thereby achieving customer satisfaction. However, the machines and equipment of
an organisation are subject to wear and tear over the years. Here, the role of
effective maintenance comes into the picture in
5
Write short notes on the following
a.
Zero based budgeting
b.
Remote maintenance audit
c.
Codification of spare parts
d.
Maintenance Benchmarking
Answer: a) It is a
method of budgeting in which all expenditures are justified each time a budget
is prepared for a new period. Zero based budgeting begins with a ‘zero base.’
Each function within the organisation is evaluated in terms of cost and
requirements for the coming fiscal year. Budgets are later prepared on the
basis of the evaluation regardless of whether the budget is higher or lower
than the previous period. In simple terms, the zero based budgeting approach
does not
6.
Case Study: Condition Monitoring at XYZ Ltd.
XYZ
Ltd. is one of the largest hydro-generating facilities in India. The
organisation has been in this business for the last 10 years. It covers a
building area of 150000 square metres and the plant area of 50000 square
metres. To manage such large plant area, the organisation has realised the need
for high machine reliability and availability. For this, XYZ has decided to implement
a condition-based monitoring (CBM) program. To make the program successful, the
organisation formed a CBM team for the implementation of the program. The team
acquired knowledge about the current condition of each machine and equipment in
the plant and identified the following loopholes in the existing maintenance
system:
·
Present
maintenance included only corrective and scheduled activities.
·
Inspections
were conducted less frequently (once in a year).
·
The
procedure followed for determining faults only contained visual inspection and
gap measurement.
·
Measures
to control contamination in oil were not present.
·
There
was no aggressive control of failure.
·
Oil
analysis was restricted to identifying haziness caused by high levels of
moisture, often past the danger point, or darkening due to advanced states of
lubricant oxidation and breakdown.
Moreover,
there were significantly high manpower requirements and maintenance costs in
the organisation. There were frequent failures of hydraulic shuttle valves that
make the unit in operational. To repair and restore these valves, the repair
crew had to perform recce of the site (an hour each way), disassemble the
valve, and repair it.
The
CBM team, after acquiring the knowledge, has realised the opportunity to
improve operating conditions of the plant through condition monitoring. Under
the guidance of the CBM team, the following changes have been implemented in
the XYZ’s plant:
·
Full-time
filtration systems including storage tanks, oil pumps, etc. are installed.
·
Finer
filtration methods are implemented to clean oil systems to tight tolerances.
·
Condition
monitoring techniques for oil analysis are implemented by defining lubricant condition
control, onsite monitoring of particle counts, viscosity, and moisture
screening.
·
Vibration
analysis is also adopted to ensure proper alignment and balance of machines’ parts
and detect abnormalities that may otherwise go unnoticed.
·
For
electrical system’s maintenance, thermography is used.
Discussion
questions:
1.
Which condition monitoring techniques have been used to improve plant
maintenance at XYZ?
2.
Do you think that the implementation of condition monitoring techniques is the
right decision of XYZ? Justify your agreement/disagreement.
Answer: 1. Condition monitoring techniques
The
CBM team, after acquiring the knowledge, has realised the opportunity to
improve operating conditions of the plant through condition monitoring.
Vibration condition monitoring: Vibrations are inherent in all machines. A vibration can be
defined as the movement of a machine in the back and forth position. It is a
parameter that can be used by maintenance personnel to detect the faults and
failures of machines and equipment. A Get fully solved assignment. Buy online from website
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if urgent then call us on 08791490301, 08273413412
