Production management means planning, organising, directing and controlling of production activities. Production management deals with converting raw materials into finished goods or products. It brings together the 6M's i.e. men, money, machines, materials, methods and markets to satisfy the wants of the people.
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Machines and equipment are the “heart” of production. If a critical machine fails, production stops, delivery schedules slip, and costs increase. Maintenance management is the discipline of keeping assets in good working condition with minimum downtime and cost while ensuring safety and product quality.
Maintenance is not only a repair activity. Modern maintenance includes planning, inspection, lubrication, condition monitoring, and continuous improvement (TPM). The main goal is high availability of machines with optimum cost.
Maintenance is the set of activities carried out to keep equipment in, or restore it to, a condition in which it can perform its required function.
Objectives:
Maintenance done after failure occurs.
Where suitable:
Drawback:
Maintenance performed at predetermined intervals to reduce probability of failure (lubrication, periodic inspection, replacement).
Maintenance based on actual condition of equipment measured using monitoring techniques (vibration analysis, thermography etc.). Repairs happen “when needed”, not only by calendar.
Typical steps:
Advantages:
Limitations:
Concept:
Common tools:
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Machines and equipment are the “heart” of production. If a critical machine fails, production stops, delivery schedules slip, and costs increase. Maintenance management is the discipline of keeping assets in good working condition with minimum downtime and cost while ensuring safety and product quality.
Maintenance is not only a repair activity. Modern maintenance includes planning, inspection, lubrication, condition monitoring, and continuous improvement (TPM). The main goal is high availability of machines with optimum cost.
Maintenance is the set of activities carried out to keep equipment in, or restore it to, a condition in which it can perform its required function.
Objectives:
Maintenance done after failure occurs.
Where suitable:
Drawback:
Maintenance performed at predetermined intervals to reduce probability of failure (lubrication, periodic inspection, replacement).
Maintenance based on actual condition of equipment measured using monitoring techniques (vibration analysis, thermography etc.). Repairs happen “when needed”, not only by calendar.
Typical steps:
Advantages:
Limitations:
Concept:
Common tools:
Benefit:
TPM is a company-wide approach to maximize equipment effectiveness by involving everyone (operators + maintenance + management). It aims for zero breakdowns, zero defects, zero accidents.
Common TPM pillars (overview):
OEE combines:
Higher OEE means better utilization of equipment.
Key terms:
Basic idea (conceptual formula used in many courses):
Increasing MTBF (fewer failures) and decreasing MTTR (faster repair) improves availability.
Planning answers “what and how”:
Scheduling answers “when”:
Good planning reduces waiting, improves coordination, and reduces downtime.
Spare parts are essential for quick repair. Poor spares management causes long downtime.
Basics:
Maintenance work has risks: electrical hazards, rotating parts, heights, hot surfaces.
Basic practices:
Identify equipment needs → Choose maintenance strategy → Plan resources → Schedule jobs → Execute → Record history → Improve plan
From this topic
Objectives of maintenance management (any four):
Thus, maintenance supports smooth production at optimum cost and high reliability.
Table:
Hence, predictive avoids both extremes: run-to-failure and over-maintenance.
Meaning: TPM is a company-wide maintenance approach focused on maximizing equipment effectiveness by involving operators, maintenance staff and management.
Conclusion: TPM creates shared ownership of equipment, reduces losses and improves OEE through systematic maintenance and continuous improvement.