MAINTENANCE ENGINEERING & MANAGEMENT

MAINTENANCE
ENGINEERING &
MANAGEMENT

1ST EDITION 2022
FAZIDA AKHTAR BINTI ABDULLAH
HJ ROSIDI BINTI MUHAMAD NOR

https://anyflip.com/vihlm/sjdz/

MAINTENANCE
ENGINEERING &
MAINTENANCE

1ST EDITION 2022
FAZIDA AKHTAR BINTI ABDULLAH
HJ ROSIDI BIN MUHAMAD NOR

COPYRIGHT • All rights reserved. No part of this publication may be reproduced.
1ST EDITION 2022 Stored in a retrieval system or transmitted in any form or by any
means, electronic, mechanical, photocopying, photographs recording,
etc without the prior permission of Politeknik Mukah.

• Author
Fazida Akhtar Binti Abdullah
Hj Rosidi Binti Muhamad Nor

e ISBN 978-967-2097-51-8 Published
POLITEKNIK MUKAH SARAW AK

KM7.5, JALAN OYA
96400 MUKAH SARAWAK

TEL : 084-874001
FAKS : 084874005
www,pmu.edu.my

PREFACE • MAINTENANCE ENGINEERING & MANAGEMENT
covering topics such as Maintenance organization,
Maintenance Strategies System, System Approach to
Maintenance, Maintenance Planning & Scheduling also
CMMS. Firstly, the book covers about the knowledge
regarding maintenance of facilities and machine in
good working condition. It also discuss the variability
in product characteristics and result in defective parts
that fail to meet the expectation specifications. The
example of maintenance strategies will provide
guidelines for any maintenance organizations to
achieve improvements. Lastly, it’s crucial that a proven
and effective maintenance approach must be
developed during the planning of maintenance
strategies to reach the vision and mission.

• editor

ABOUT AUTHOR

HJ ROSIDI BIN MUHAMAD NOR
PENSYARAH TEKNIK
POLITEKNIK MUKAH
DH 52
[email protected]

FAZIDA AKHTAR BINTI ABDULLAH
PENSYARAH TEKNIK
POLITEKNIK MUKAH
DH 48
[email protected]

TABLE OF MAINTENANCE ORGANIZATION
CONTENTS
• CHAPTER 1

MAINTENANCE STRATEGIES/ TYPES/ SYSTEM

• CHAPTER 2

SYSTEM APPROACH TO MAINTENANCE

• CHAPTER 3

MAINTENANCE PLANNING & SCHEDULING

• CHAPTER 4

COMPUTERIZED MAINTENANCE MANAGEMENT SYSTEM

• CHAPTER 5

LEARNING OUTCOMES
Upon Completing the chapter, students should be able to

i. state the objectives and benefits of management
management

ii. Classify types of management organizations
iii. Different types of responsibilities/roles in maintenance

management organization.

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WHAT IS MAINTENANCE MANAGEMENT
- Involves keeping track of assets and parts.
– Organizing is the process of arranging resources together

to achieve the organization’s strategies and goals.
Resources: People, practices, materials, technology, tools,
equipment, database etc

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WHAT IS MAINTENANCE MANAGEMENT
- Mainly to ensure the production proceeds efficiently
- Minimum amount of resources are wasted
- The way various parts are arranged formally is referred

as The Organization Structure.

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– It a system involving the interaction of inputs and outputs.
– Any structure must allocate tasks through a division of labor and facilitate the

coordination of the performance results through assignments, workflow, report
relationships and communication channels that link together the work of diverse
individuals and groups.
– Nevertheless, organization structures should be viewed as dynamic entities that
continuously evolve to respond to changes in technology, processes and environment.

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5 mains objectives are:
i. Budgeting
ii. Scheduling work
iii. Regulation compliance
iv. Optimizing work
v. Improving safety

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– The maintenance organizing function can be viewed as one of the basic and
integral parts of the Maintenance Management Function (MMF).

– It consists of;
– Planning
– Organizing
– Implementing
– Controlling maintenance activities.

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Accomplishing
Targets

Performing Tasks

Provides resources

DJJ 50212 MAINTENANCE ENGINEERING AND MANAGEMENT

– In designing the maintenance organization, there are important determinants that must be
considered:
– Capacity of maintenance
– Maintenance manager must have capabilities to create a division of labor for
maintenance tasks to be performed and then coordinate results to achieve a common
purpose
– centralization versus decentralization
– A decentralization structure would probably experience a lower utilization than
centralized one but would be able to respond quickly to breakdown.
– In-house maintenance versus outsourcing

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Maintenance Organization

1.2 ROLE OF MAINTENANCE ORGANIZATION
1.2.1 Objective & Benefits
Elements that impacts the positioning in maintenance organizing plants
are;
- type of business
- objectives: may include profit maximizing, increase market share and

other social objectives
- size and structure of the organization
- culture of the organization
- range of responsibilities assigned to maintenances

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1.2 ROLE OF MAINTENANCE ORGANIZATION

OBJECTIVES CLASSIFICATIONS
&
TYPES OF ROLE/
BENEFITS RESPONSIBILITIES

MAINTENANCE
ORGANIZATION

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Maintenance Organization

– The principle responsibility of maintenance is to provide service to
enable an organization to achieve its objectives.

– In general they need to;
– Keep assets and equipment in good condition, well configured and
safe to perform their intended functions
– Perform all maintenance activities
– Conserve and control the use of spare parts and materials
– Commission new plants and plant expansions
– Operate utilities and conserve energy

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planning

controlling Leader’s organizing
influence

implementing

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Maintenance Organization

1.2.1.1 Maintenance capacity planning
– Required resource for maintenance including
– Crafts
– Administration
– Equipment
– Tools
– Space
To execute the maintenance load efficiency and meet the department
objectives.

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Maintenance Organization

1.2.1.2 Centralization Vs Decentralization
(the decision to organize central, decentral or hybrid is depends on the organization).

The advantage of centralization Disadvantage of centralization

Provide more flexibility and improve – Less utilization of crafts (more time
utilization of resources required)
Allow more efficient line supervision
Allow more effective on the job training – Supervision more difficult (Less
Permit the purchasing of modern maintenance control is achieved)
equipment
– Less specialization on complex
DJJ 50212 hardware is achieve

– More costs of transportation are
incurred due to remoteness of some
of the maintenance work.

Maintenance Organization

– For decentralized maintenance, its tends to reduce the flexibility of the
maintenance as a whole.

– The range of skills available become reduced and manpower utilization is
usually less efficient.

– Hybrid is called cascade system. Its organize maintenance in area and whatever
exceeds the capacity of each area.

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Maintenance Organization

1.2.1.3 In house Vs Outsourcing
– The option are available either in house or outsourcing or combination of in-house and outsource
– The criteria selected include strategic consideration, technological and economic factors.
– The criteria that can be employed are;
– Availability and dependability of the source on the long term basis
– Capability of the source to achieve the objectives set for maintenance by the organization and its
ability to carry out the maintenance tasks
– Short terms and long terms cost
– Organization secrecy may subject to leakage
– Long term impact on maintenance personnel expertise
– Special agreement by manufacturer or regulatory bodies that set certain specification for the
maintenance and environmental emissions.

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Maintenance Organization

1.2.2 CLASSIFICATION

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Maintenance Organization

Decentralized

– For large size plants located at different places, communication for inter unit is
quite difficult.

– In such cases, the decentralized type of organization is the best suited, where
the maintenance organization works under the direct control of chief engineer
in-charge of production.

– The advantages are;

– Speedy decision due to better line of communication under single control
– Maintenance and production groups understand each other’s problem better

because of their common goals.
– Interchangeability of workforce, even at the managerial level, is also possible
– Better training at the works’ level can be arranged.

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Maintenance Organization

Centralized

– For small size factory where communication between the department is freer.
– In such cases, centralized type of organization is the best suited under

maintenance chief engineer/manager.
– The total responsibility for maintenance function is chief maintenance engineer.

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Maintenance Organization

Partially decentralized

– It is the modified form of centralized type of organization.
– In such cases, it is most suitable for project that have units far away locations.
– Under this type of maintenance organization, the maintenance personnel,

attached to production unit, carry out work at unit level and look after day to
day maintenance.
– All centralized work pertaining to maintenance planning and documentation is
done at level of central maintenance workshop.

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Maintenance Organization

1.2.3 Types Of Rules/Responsibilities

PRIMARY SECONDARY
FUNCTIONS FUNCTION

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OF

RULES

Maintenance Organization

PRIMARY FUNCTION

UTILITIES MAINTENANCE MAINTENANCE
GENERATION OF EXISTING OF EXISTING
PLANT PLANT
& BUILDING & EQUIPMENT
DISTRIBUTION GROUNDS

PRIMARY
FUNCTION

ALTERATIONS EQUIPMENT
& NEW INSPECTION &
LUBRICATION
INSTALLATIONS

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CHAPTER 1
MAINTENANCE ORGANIZATION

1.3 MAINTENANCE COSTS
– The cost of maintenance is defined as costs that include

lost opportunities in uptime, rate, yield and quality due
to non-operating or unsatisfactorily operating equipment
in addiction to costs involved with

– Equipment-related degradation of the safety of people
– Property, and
– Environment.

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Maintenance Organization

PRIMARY FUNCTION

STOREKEEPING

OTHER SERVICES SECONDARY PLANT
FUNCTION PROTECTION
INSURANCE
ADMINISTRATION WASTE DISPOSAL

SALVAGE

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Maintenance Organization

1.3.1 Sources

– Significant factor in an organization’s profitability.
– Basic definition of profit is “Profit = Income – Expenses”.
– Factors that associated with the maintenance expenditure are;

– Downtime
– Idle equipment or personal due to equipment breakdown
– Missed delivery dates of equipment
– Transportation due to remoteness of the some of the maintenance work
– Overheat cost
– Maintenance labor
– Asset condition
– Loss due to inefficient operations of machine
– Capital requirement for replacement of machines

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Maintenance Organization

– Examples of maintenance costing are:

– Determine maintenance cost drivers
– Prepare budget
– Provide input in the design of new equipment/item/system
– Provide input in equipment life cycle cost studies
– Control costs
– Make decisions concerning equipment replacement
– Compare maintenance cost effectiveness to industry avengers
– Develop optimum preventive maintenance policies
– Compare competing approaches to maintenance
– Provide feedback to upper level management
– Improve productivity

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Maintenance Organization

1.3.2 Types

– There are several types of maintenance cost that is related to maintenance work:

– Direct cost
– Standby cost
– Lost production cost
– Degradation cost

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Maintenance Organization

– The life cycle costing plays an important role in maintainability analysis, particularly with respect to operation and
maintaining costs.

– The aim of life cycle costing is to know the total cost of equipment accruing over its whole life period, which may
include all the cost starting from the specification cost.

– The total cost has to be therefore optimized by making trade-off among all elements of it.
– The data to be input into life cycle cost model include;

– Purchase price of the product
– Mean time between failures (MTBF)
– Mean time to repair (MTTR)
– Average material cost of a failure
– Labor cost per preventive maintenance action
– Labor cost per corrective maintenance action
– Installation cost
– Training cost
– The warranty coverage period cost of carrying spares in inventory
– ShipmeDntJfJo5re0c2a1s2ts over course of the product’s useful life

Maintenance Organization

1.3.3 Cost Analysis Methods

– The life cycle cost is the sum of all costs incurred during the life time of an item.
– Due to reason including market pressure, life cycle costing often used in the procurement of

expensive system or equipment.
– Life cycle cost analyses involve evaluating the total cost of a product or system over its entire

life span.
– Life cycle cost will consider ;

– the cost of developing or acquiring,
– The asset, the cost of running, operating and maintain
– The cost of disposal

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Maintenance Organization

when applying the life cycle cost analysis,

Several major advantages can A little advantages
be achieve;
– Time consuming
❖ It may result in selection of equipment that – Expensive
has lower operating and maintenance costs
resulting in reduced cost of ownership The collecting data needed for
analysis can be a trying task, and that
❖ The money saved can be used for some data available is sometimes of
other works doubtful accuracy.

❖ It is an excellent tool for comparing the cost
of competing project, controlling program
costs, selecting among competing
contractors, making decisions associated
with equipment replacement, reducing total
cost

DJJ 5❖0212Conducting planning and budgeting

EXAMPLE

– THE RECORD FOR A MACHINE BREAKDOWN FOR COMPANY FAA FOR THE PAST
25 MONTHS IS SHOWN BELOW

# OF # OF MONTHS BREAKDOWN
BREAKDOWN OCCURS
4
0 5
1 7
2 9
3
TOTAL 25 MONTH

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additional info;

#1 – each time the machine breakdown – estimated loss is RM 450
#2 – contract preventive maintenance by Company GA – RM 300
per month
#3 – should FAA contract out preventive maintenance to GA?

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Questions

– #1
– Calculate expected number of breakdown (based on past records) if the company continue
without service contract.
#2
- Compute expected breakdown cost per month with no preventive maintenance contract
#3
- Compute the cost of preventive maintenance
#4
- Compare the two options and select the one which cost is less.

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Solution;

– # 1;
– Expected # of breakdown = [(# of breakdown) x (frequency)]

# OF BREAKDOWN # OF MONTHS THE FREQUENCY
BREAKDOWN OCCURS
– = 4/25 = 0.16 *0 = 0
4 = 5/25 = 0.2*1 = 0.2
0 5 = 7/25 = 0.28*2 =0.56
7 = 9/25 = 0.36*3=1.08
1 9
25 MONTH =1.84
2

3

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– #2
Expected breakdown cost = (expected # of breakdown) x

(cost per breakdown)
= (1.84 ) x 450 = RM 828 per month

- #3
Calculate Preventive Maintenance Cost
= cost of expected breakdown + cost of service contract
= (1 breakdown per month x 450) + RM300 per month
= RM 750

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– #4 With service Without service
Compare contract contract
1.0 1.0
Expected # of
breakdown 828 828

Expected breakdown =828+300 828
cost =1128
More Less
Preventive
maintenance cost

Therefore, continue present policy which is the breakdown maintenance
because its less expensive.

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Maintenance Organization

the relationship between the maintenance commitment and maintenance cost:

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LEARNING OUTCOMES:-

CHAPTER 2
MAINTENANCE STRATEGIES

2.1 INTRODUCTION

 In this chapter, there various outline
maintenance strategies that you can combine
to develop an overall plant maintenance
strategy and make a dent in those rising costs.

 Without a well thought out maintenance
strategy, you may see patterns like these in your
operation:-

Maintenance STRATEGIES

i. Equipment failures result in lost production and expensive repairs.
ii. The same equipment failures happen again and again
iii. Maintenance schedules are the same for all similar equipment,

regardless of application or economic impact.
iv. No maintenance standard or best practices exist.
v. A good maintenance strategy can address all of these symptoms,

improving process operations while reducing costs.

In facts, maintenance strategies as important as your business results as your
quality program.

Maintenance STRATEGIES
2.2 Maintenance Strategies

 Maintenance STRATEGY means a scheme for maintenance, i.e an elaborate
and systematic plan of maintenance action.

 So, it’s a long term plan, covering all aspects of maintenance management
which sets the direction for maintenance management, and contains firm
action plans for achieving a desired future state for the maintenance function.

 Several maintenance strategies are mainly used in technical system.

 The most common strategies are: corrective, time-based, condition-based and
reliability-centered maintenance.

Maintenance STRATEGIES

2.2.1 Functions

Maintenance Function ensures that all the machines and
equipment related to the production and other key functions
in the organization are maintained and function properly.

Maintenance functions will be limited to and defined as
follows:

Maintenance STRATEGIES

Maintenance STRATEGIES

2.2.2 BASIC SELECTION

1 • Establish business requirement
2 • Carry out equipment audit
3 • Carry out reliability & criticality audit
4 • Select appropriate maintenance strategy/task
5 • Plan work, issue work & carry out work
6 • Record results & determine any further maintenance action
7 • Review & measure effectiveness