MAINTENANCE FUNDAMENTALS

MACHINES AND MECHANISMS
October 1, 2018
Machining and CNC Technolog
October 3, 2018

MAINTENANCE FUNDAMENTALS

MAINTENANCE FUNDAMENTALS

Book Details

Pages : 425
Size : 6.6 MB

Book Description

Maintenance costs, as defined by normal plant accounting procedures, are
normally a major portion of the total operating costs in most plants. Traditional
maintenance costs (i.e., labor and material) in the United States have escalated at
a tremendous rate over the past 10 years. In 1981, domestic plants spent more
than $600 billion to maintain their critical plant systems. By 1991, the costs had
increase to more than $800 billion, and they were projected to top $1.2 trillion by
the year 2000. These evaluations indicate that on average, one third, or $250
billion, of all maintenance dollars are wasted through ineffective maintenance
management methods. American industry cannot absorb the incredible level of
inefficiency and hope to compete in the world market.
Because of the exorbitant nature of maintenance costs, they represent the
greatest potential short-term improvement. Delays, product rejects, scheduled
maintenance downtime, and traditional maintenance costs—such as labor,
overtime, and repair parts—are generally the major contributors to abnormal
maintenance costs within a plant.
The dominant reason for this ineffective management is the lack of factual data
that quantify the actual need for repair or maintenance of plant machinery,
equipment, and systems. Maintenance scheduling has been and in many in-
stances still is predicated on statistical trend data or on the actual failure of
plant equipment.
Until recently, middle and corporate level management have ignored the impact
of the maintenance operation on product quality, production costs, and more
importantly on bottom-line profit. The general opinion has been ‘‘maintenance is
a necessary evil’’ or ‘‘nothing can be done to improve maintenance costs.’’
Perhaps these were true statements 10 or 20 years ago. However, the develop-
ments of microprocessor or computer-based instrumentation that can be used to
monitor the operating condition of plant equipment, machinery, and systems
have provided the means to manage the maintenance operation. They have
provided the means to reduce or eliminate unnecessary repairs, prevent cata-
strophic machine failures, and reduce the negative impact of the maintenan

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