Maintenance Lecture Notes for senior class

Chapter One
General Introduction to Maintenance

Maintenance
“Maintenance” means to keep equipments,
machines or systems in operational condition or
repair it to its operational mode.
Its main components are:
 Preventive Maintenance
 Corrective Maintenance
Preventive Maintenance is the maintenance which is
carried out to prevent/avoid the upcoming breakdowns.
Corrective Maintenance is the maintenance which is

 It is the art that is intended to retain a machine or an
equipment or restore it to, a state in which it can perform a
required function or an operation.
 It is the discipline and profession of applying engineering
concepts to the optimization of equipments, procedures to
achieve better reliability and availability of equipments.
 It is the art, science and philosophy that aides in increased
productivity and has become the most important component
of plant maintenance.
Maintenance Engineering
Its main objective is to ascertain that the new products are
designed for ease of performing maintenance and that the
proper economic support subsystem is provided at the
moment of need.

In general,
 All actions necessary for retaining an item, or restoring to it, a
serviceable condition, include servicing, repair, modification,
overhaul, inspection and condition verification.
 Increase availability of a system.
 Keep system’s equipment in working order are the main role of
maintenance Engineering.

It’s purpose
 The main purpose of maintenance in an industrial
perspective is to reduce the business risks.
 Production capacity, productivity and business profit mainly
depends on maintenance operations.
 Its main purpose is to support ,configure, diagnose , repair,
update and mange a equipment throughout it’s life cycle.
 In general maintaining all equipments at its full functionality
and helping productivity is the main function of maintenance
engineering.
1. Attempt to maximize performance of production
equipment efficiently and regularly.
2. Prevent breakdown or failures.
3. Minimize production loss from failures.
4. Increase reliability of the operating systems.

 With the increased complexity, sophistication and
automation of the equipments and systems , a heavy
burden falls on maintenance engineers regarding the
quality and quantity of maintenance , maintenance aids,
documentation etc.,
 The current scenario is that today’s jobs and problems
cannot be solved with yesterday’s tools and techniques.
So continuous development is needed in maintenance
areas to tackle today’s need and also anticipated need
of tomorrow.

Principle Objectives in Maintenance
1. To achieve product quality and customer satisfaction
through adjusted and serviced equipment.
2. Maximize useful life of equipments.
3. Keep equipments safe and prevent from hazards.
4. Minimize frequency and severity of interruptions.
5. Maximize production capacity – through high utilization of
facility.

Maintenance Objectives
PLANT
M
A
I
N
T
E
N
A
N
C
E
Reduce Breakdowns
Reduce Downtime
Improving Equipment
Efficiency
Improving Inventory
Control
Implementing Cost
Reduction
Maximising Production
Optimising Resources
Utilisation
Optimising Useful Life
of Equipment
Minimising Energy
Usage
Providing Budgetary
Control
Figure 2.3 Maintenance Objectives

Maintenance Lecture Notes for senior class

Types of Maintenance
 Run to Failure Maintenance (RTF)
 Preventive Maintenance (PM)
 Corrective Maintenance (CM)
 Improvement Maintenance (IM)
 Predictive Maintenance (PDM)

Run to Failure Maintenance (RTF)
 The required repair, replacement, or restore action
performed on a machine or a facility after the
occurrence of a failure in order to bring this
machine or facility to at least its minimum
acceptable condition.
 It is the oldest type of maintenance.

 It is subdivided into two types:
 Emergency maintenance: it is carried out as fast as
possible in order to bring a failed machine or facility to a
safe and operationally efficient condition.
 Breakdown maintenance: it is performed after the
occurrence of an advanced considered failure for which
advanced provision has been made in the form of repair
method, spares, materials, labour and equipment.

Disadvantages:
1. Its activities are expensive in terms of both direct and
indirect cost.
2. Using this type of maintenance, the occurrence of a failure
in a component can cause failures in other components in
the same equipment, which leads to low production
availability.
3. Its activities are very difficult to plan and schedule in
advance.

This type of maintenance is useful in the following situations:
1. The failure of a component in a system is unpredictable.
2. The cost of performing run to failure maintenance activities
is lower than performing other activities of other types of
maintenance.
3. The equipment failure priority is too low in order to include
the activities of preventing it within the planned
maintenance budget.

Preventive Maintenance (PM)
It is a set of activities that are performed on plant
equipment, machinery, and systems before the
occurrence of a failure in order to protect them and
to prevent or eliminate any degradation in their
operating conditions.

British Standard 3811:1993 Glossary of terms
defined preventive maintenance as:
the maintenance carried out at predetermined
intervals or according to prescribed criteria and
intended to reduce the probability of failure or the
degradation of the functioning and the effects
limited.

 The advantage of applying preventive maintenance
activities is to satisfy most of maintenance
objectives.

The factors that affect the efficiency of this type of maintenance:
1. The need for an adequate number of staff in the maintenance
department in order to perform this type of maintenance.
2. The right choice of production equipment and machinery that is
suitable for the working environment and that can tolerate the
workload of this environment.
3. The required staff qualifications and skills, which can be gained
through training.
4. The support and commitment from executive management to the
PM programme.
5. The proper planning and scheduling of PM programme.
6. The ability to properly apply the PM programme.

 It is good for those machines and facilities which
their failure would cause serious production losses.
 Its aim is to maintain machines and facilities in
such a condition that breakdowns and emergency
repairs are minimised.
 Its activities include replacements, adjustments,
major overhauls, inspections and lubrications.

 Researchers subdivided preventive maintenance into
different kinds according to the nature of its activities:
 Routine maintenance which includes those maintenance
activities that are repetitive and periodic in nature such as
lubrication, cleaning, and small adjustment.
 Running maintenance which includes those maintenance
activities that are carried out while the machine or
equipment is running and they represent those activities that
are performed before the actual preventive maintenance
activities take place.

 Opportunity maintenance which is a set of maintenance
activities that are performed on a machine or a facility when
an unplanned opportunity exists during the period of
performing planned maintenance activities to other machines
or facilities.
 Window maintenance which is a set of activities that are
carried out when a machine or equipment is not required for
a definite period of time.
 Shutdown preventive maintenance, which is a set of
preventive maintenance activities that are carried out when
the production line is in total stoppage situation.

Corrective Maintenance (CM)
 In this type, actions such as repair, replacement, or restore
will be carried out after the occurrence of a failure in order
to eliminate the source of this failure or reduce the
frequency of its occurrence.
In the British Standard 3811:1993 Glossary of terms,
corrective maintenance is defined as:
the maintenance carried out after recognition and intended to
put an item into a state in which it can perform a required
function.

 This type of maintenance is subdivided into three
types:
 Remedial maintenance, which is a set of activities
that are performed to eliminate the source of failure
without interrupting the continuity of the
production process.
The way to carry out this type of corrective maintenance is
by taking the item to be corrected out of the production line
and replacing it with reconditioned item or transferring its
workload to its redundancy.

 Deferred maintenance, which is a set of corrective
maintenance activities that are not immediately
initiated after the occurrence of a failure but are
delayed in such a way that will not affect the
production process.
 Shutdown corrective maintenance, which is a set of
corrective maintenance activities that are performed
when the production line is in total stoppage
situation.

 The main objectives of corrective maintenance are the
maximisation of the effectiveness of all critical plant
systems, the elimination of breakdowns, the elimination of
unnecessary repair, and the reduction of the deviations from
optimum operating conditions.
 The difference between corrective maintenance and
preventive maintenance is that for the corrective
maintenance, the failure should occur before any corrective
action is taken.
 Corrective maintenance is different from run to failure
maintenance in that its activities are planned and regularly
taken out to keep plant’s machines and equipment in
optimum operating condition.

 The way to perform corrective maintenance activities is by
conducting four important steps:
1. Fault detection.
2. Fault isolation.
3. Fault elimination.
4. Verification of fault elimination.
In the fault elimination step several actions could be taken
such as adjusting, aligning, calibrating, reworking,
removing, replacing or renovation.

 Corrective maintenance has several prerequisites in
order to be carried out effectively:
1. Accurate identification of incipient problems.
2. Effective planning which depends on the skills of the
planners, the availability of well developed maintenance
database about standard time to repair, a complete repair
procedures, and the required labour skills, specific tools,
parts and equipment.
3. Proper repair procedures.
4. Adequate time to repair.
5. Verification of repair.

Improvement Maintenance (IM)
 It aims at reducing or eliminating entirely the need for
maintenance.
 This type of maintenance is subdivided into three types as
follows:
1. Design-out maintenance which is a set of activities that
are used to eliminate the cause of maintenance, simplify
maintenance tasks, or raise machine performance from the
maintenance point of view by redesigning those machines
and facilities which are vulnerable to frequent occurrence of
failure and their long term repair or replacement cost is very
expensive.

Improvement Maintenance (IM)
2. Engineering services which includes construction and
construction modification, removal and installation, and
rearrangement of facilities.
3. Shutdown improvement maintenance, which is a set of
improvement maintenance activities that are performed
while the production line is in a complete stoppage situation.

Predictive Maintenance (PDM)
 Predictive maintenance is a set of activities that detect
changes in the physical condition of equipment (signs of
failure) in order to carry out the appropriate maintenance
work for maximising the service life of equipment without
increasing the risk of failure.
 It is classified into two kinds according to the methods of
detecting the signs of failure:
 Condition-based predictive maintenance
 Statistical-based predictive maintenance

 Condition-based predictive maintenance depends on
continuous or periodic condition monitoring equipment to
detect the signs of failure.
 Statistical-based predictive maintenance depends on
statistical data from the meticulous recording of the
stoppages of the in-plant items and components in order to
develop models for predicting failures.

 The drawback of predictive maintenance is that it depends
heavily on information and the correct interpretation of the
information.
 Some researchers classified predictive maintenance as a type
of preventive maintenance.
 The main difference between preventive maintenance and
predictive maintenance is that predictive maintenance uses
monitoring the condition of machines or equipment to
determine the actual mean time to failure whereas preventive
maintenance depends on industrial average life statistics.

Types of Maintenance
MAINTENANCE
UNPLANNED
MAINTENANCE
(REACTIVE)
BREAKDOWN
EMERGENCY
PLANNED
MAINTENANCE
(PROACTIVE)
CORRECTIVE
MAINTENANCE
REMEDIAL
DEFERRED
PREDECTIVE
MAINTENANCE
CONDITION -
BASED
STATISTICAL
- BASED
PREVENTIVE
MAINTENANCE
ROUTINE
RUNNING
DESIGN - OUT
ENGINEERING
SERVICES
WINDOW
IMPROVEMENT
MAINTENANCE
SHUTDOWN
CORRECTIVE
SHUTDOWN
PREVENTIVE
SHUTDOWN
IMPROVEMENT
Shutdown Maintenance
OPPORTU-
NITY
Figure 2.4 Maintenance Types

Assignment 1
Last date of submission 29/05/21

Maintenance Lecture Notes for senior class

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Maintenance Lecture Notes for senior class