In the 20th century, the economic value of industrial maintenance was first recognized. Today, it is one of the few strategies for lowering production costs and total cost of ownership for physical assets. The need for maintenance specialists in the industry has risen as a result.
The goal of the maintenance course is to increase the learners' competence, knowledge, and skill sets. It covers areas like maintenance introduction, equipment failure statistics, equipment failure probability distributions, maintenance types and their comparison, maintenance costs, organizational growth, formulation and implementation of maintenance programs, employee involvement, planning and scheduling, equipment replacement policies, reliability and its improvement, maintenance economy, maintenance strategies, planning and control of spares, work-study for maintenance, operations research techniques in maintenance, maintenance organization, safety and its objectives.
The course provides the basic knowledge regarding the aspects of reliability and maintainability of industrial plants with particular reference to safety aspects
Learning Objectives
The course aims to deliver the following learning objectives:
The course would utilize various tools- Books, Journal Papers, Popular Readings, Case Studies and Simulations. The classroom session would involve a discussion of the critical concepts, case study discussions and quantitative simulations. This would be supplemented with assignments and exams.
Learning Through Case Method: Effective learning through the case method requires four stages of learning (individual preparation, group discussion, class discussion, and after-class reflection). To make the best use of the learning opportunity following steps may be followed:
To make the best use of the learning opportunities, the following steps may be followed:
Laboratories:
The course will use mostly Excel, Taras, and SLAB in these students should be able to do the following:
The laboratory-based case method requires students to prepare a decision, to the extent available, based on careful evaluation of case facts and numbers. As with all business situations, there may be insufficient facts, ambiguous goals, and strong dynamic/uncertain environments. Students, finally, will develop the following skills:
Course Outline: Session/Topic/Reading Material/Reference
Session
Topics
Learning Outcomes
Readings and Cases
1-2
Introduction to Maintenance: Types and Comparison
In this lecture, an introduction to Maintenance and its types is given. Specifically, the following points are reviewed in the chapter. Maintenance background, four questions in maintenance, management role in maintenance, cost comparison between breakdown and preventive maintenance
Production and Operations Management by N G NAIR (chapter 07)
3
Failure statistics
Importance of failure statistics, failure statistic types, bath-tub contour, related exercises and Weibull's probability distribution
4-5
Equipment Effectiveness,
In this lecture, the following topics have been covered Equipment Effectiveness, Equipment losses, Maintainability, Reliability and Availability. Maintenance efficiency, ways of scheduling PM
Exercises related to Reliability
Competitive Manufacturing Management
TATA McGraw-Hill edition (chapter 07)
6-7
Maintenance Repair & Replacement Plan (MRRP)
In these lectures, details of the Maintenance Repair & Replacement Plan (MRRP) are discussed—specifically, the benefits of a Maintenance Repair & Replacement Plan (MRRP). In addition, replacement problems/exercises have been added.
Production and Operations Management by R. Paneerselvam (chapter 19)
8
Preventive Replacement
Preventive replacement and its exercises, managing maintenance information and the role of operators for the above
9
To Study
Taras Software
10
Reliability
This lecture discussed 'Reliability' in detail. Complete procedure for Reliability Program has been discussed in detail. Few more exercises for reliability
11-12
Total Productive Maintenance (TPM)
Different aspects of Total Productive Maintenance have been discussed. Important topics included are waste eliminated in TPM, pillars of TPM, and Implementation of TPM.
Difference between Central Maintenance and decentralization.
13
SLAB Software
14-15
Maintenance Economy and OR
Maintenance Economy is an important aspect of maintenance management. The maintenance organizational structure has been discussed. Also, Operations research techniques have been discussed in this chapter.
16
Spares Management
Spares Management is a vital component of maintenance. The following topics related to spares management have been discussed. Planning and Control of Spare Parts,
Effective Spare Parts Inventory and Management
Classification of Spares
And work-study in maintenance
Production and Operations Management by S N Charry (chapter 09)
17
Safety
In this lecture, the following topics have been covered safety objectives, workplace safety, hazardous material handling, ladders, and scaffolds.
Industrial Maintenance by Michael E. Brumbach and Jeffrey A. Clade (Second edition, Chapter 01)
18
Mechanics and structures
The objective is to examine some of the principles and how they relate to safety.
Operators must consider the types and amounts of forces that act or may act on systems, equipment, and products to make them safe.
Safety and Health for Engineers, Roger L. Brauer 3rd edition (chapter 10)
19
Walking and Working Surfaces
Numerous accidents, injuries, and fatalities are caused by the surfaces and equipment that people use to stand, walk, work, and climb.
They cause a significant cost. This lecture will examine a few of the surfaces, pieces of machinery, and design elements that cause falls, their associated injuries, and fatalities.
Safety and Health for Engineers, Roger L. Brauer 3rd edition (chapter 11)
20
Tools and machine hazards
Most injuries are caused by equipment and tools. About 8% of lost-time occupational accidents are caused by hand tools; machines account for a larger portion. Injuries are frequently more severe while using powered tools and equipment than when using hand-operated ones because they require significant amounts of energy and power.
Safety and Health for Engineers, Roger L. Brauer 3rd edition (chapter 13)
21
Fire Protection and Prevention
This lecture discussed importance of fire Protection, alongside its causes and costs.
The physics and chemistry of the fire.
Safety and Health for Engineers, Roger L. Brauer 3rd edition (chapter 16)
22
Visual Environment
This lesson tends to the visual environment, which incorporates lighting, variety, and signage. Numerous parts of the visual environment add to mishaps while other characteristics assist with preventing them. Students need to comprehend the visual environment.
Safety and Health for Engineers, Roger L. Brauer 3rd edition (chapter 20)
23
Noise and Vibration
Sound is an important characteristic of the environment and provides information and communication. This lecture is about the difference between sound and noise, their physics and propagation.
Safety and Health for Engineers, Roger L. Brauer 3rd edition (chapter 23)
24
Personal Protective Equipment (PPE)
PPE is the last solution if one cannot eliminate or control hazards. This lesson is about PPEs for different organs.
Safety and Health for Engineers, Roger L. Brauer 3rd edition (chapter 28)
25
Ergonomics
Ergonomics has become an important element of safety. This lesson aims at different parts of ergonomics and safety and health applications for them. Different sections include anthropometry, displays and controls, work physiology and biomechanics
Safety and Health for Engineers, Roger L. Brauer 3rd edition (chapter 33)
Recommended Textbook
Course Reading Material:
References:
Note to teaching material
The teaching material consists of transparencies, notes and other material collected by the lecturer from publications, public domain documents, websites and current legislation. Each set of transparencies bears at the bottom the bibliography and the sources cited where these have been identified. For material collected from the web where it has not been possible to identify the author or copyright holder, the wording "material not traceable to the copyright holder" has been added.
Ricevimento: The reception is to be arranged with the lecturer by appointment by sending an email to: roberto.revetria@unige.it The lecturer is available in the office every week except August.
https://corsi.unige.it/en/corsi/8720/studenti-orario
The exam is composed of three main parts:
The final grade is the average of (quiz + assignments) and oral examination.
The oral examination is based on a presentation on a course topic chosen by the student and 3 open questions by the teacher.
The exercises (assignments) must be delivered to the address: assignments.revetria@dime.unige.it by the exam day. Late exercises are not accepted. The exercises done in groups must report on all in the name of the group members. Similar exercises that do not correctly name the group members will be waived.
For every wrong question given at quiz time -0.5 points are subtracted.
The learning assessment aims to ascertain understanding and knowledge of the topics covered and the ability to apply the skills acquired to practical cases. With this in mind, the student is asked to carry out two assigments applying the formulae, models, procedures and software learned during the course to real industrial cases. The learning assessment also evaluates the student's ability to communicate in a field very close to the real work situation by presenting a calculation report.
The course also includes tutorials and seminar activities by experienced professionals.
