Philosophy of Maintenance

defined as the "upkeep of property". Involves restoration of tolerances trhough a series of intelligent compromises.

Total Productive Maintenace
Combining the practice of preventive maintenance & total quality control & total employee involvement results in an innovative system for equipment maintenance that optimizes effectiveness, eliminates breakdowns & promotes autonomous operator maintenance through day to day activity. The concept known as Total Productive Miantenance (TPM), Seiichi Nakajima.

Life Cycle Cost
Selection of all equipment.

Performance Based Total Productive Maintenance System
Combination of total condition monitoring & the maintenance principles of total productive maintenance.

5 P's for major maintenace for power plant

1. Panic maintenance based on breakdowns
2. Preventive maintenance
3. Performance based maintenance
4. Performance productive maintenance
5. Performance based total productive maintenance (PTPM)

PTPM consists of the following elements :-

1. To maximize equipment efficiency & time between overhaul.
2. To maximize equipment effectiveness.
3. Establishes a through system of PM for the equipment's entire life span.
4. Impremented by various departments (engineering, operations, maintenance).
5. Involves every single employee, from top management to workers on the floor.
6. Based on the promotions of PM through motivation management; autonomous small group activities.

'Total' means ;

1. Total overall performance effectiveness indicates PTPM's pursuit of maximum plant efficiency & minimum downtime.
2. Pursuit of economic efficiency @ profitability.
3. Total maintenance system; Maintenance prevention & maintenance improvement (MP/MI).
4. Total participation of all employees, autonomous, small group activities.

Down time :

1. Loss of time due to unnecessary overhauls based only on time intervals.
2. Equipment failure-from breakdowns.
3. Loss of time due to spare part unsuitability @ insufficient spares.
4. Idling & minor stoppages - due to the abnormal operation of sensors or other protective devices.
5. Reduced output - due to discrepancies between designed & actual operating conditions.

Defect :

1. Process defects - due to improper process conditions that do not meet machinery design requirements.
2. Reduced yiled - from machine start up to stable production due to the inability of the machine to operate at proper design conditions.