Chapter 1: Introduction

Outline of the chapter:

1.1 Definition of Maintenance
1.2 Importance of Maintenance (why do use)
1.3 Where should Maintenance to Practice
1.4 Terms used engineering maintenance
1.5 Objectives of Maintenance
1.6 Types of Maintenance
1.7 Elements of maintenance
1.8 decision making
1.1. Definition of Maintenance
 It is the combination of all technical and administrative
actions, including supervision actions.
 It is intended(supposed) to retain (keep on) an item in, or
restore it to, a state in which it can perform a required
function.
 All actions necessary for retaining(keep on) an item, or
restoring to it, a serviceable condition, include servicing,
 Repair,
 Modification,
 Overhaul,( inspection and repair)
 Inspection and
 condition verification
1.2 Importance of Maintenance (why do use)

 To have organized working system

 To schedule on Idle workers and facility
 To overcome losses due to breakdown
 To maximize performance of the equipment
 To identify where/when should failures prevent
 To Minimize production loss
 To increase reliability of the operating systems
 To maximize profitability of the company
 1.3 Where should Maintenance to Practice
Maintenance in Service Maintenance in
Industry Manufacturing Industry

• Hospital • Electronic

• Restaurants • Automotive

• Transport companies • Petrochemicals

• Banks • Refinery

• Hotels and resorts • Furniture

• Shopping malls / retail • Ceramics

• Gas station • Food and beverages

1.4 Terms used engineering maintenance
Maintenance
 All actions appropriate for retaining an item/part/equipment in, or
restoring it to, a given condition.
Maintenance engineering
 The activity of equipment/item maintenance that develops concepts,
criteria, and technical requirements in conception to be used and
maintained in a current status during the operating phase to assure
effective maintenance.
Preventive maintenance ( daily maintenance: cleaning,
inspection ... )(avoids sudden failure)
 All actions carried out on a planned, periodic, and specific schedule
to keep an item/equipment in stated working condition through the
Corrective maintenance(done after sudden assest failure)
 The unscheduled maintenance or repair to return items/equipment
to a defined state and carried out because maintenance persons
perceived (sensed) the deficiencies or failures.
Predictive maintenance
 The use of modern measurement and signal-processing methods to
accurately diagnose(analyse) item/equipment condition during
operation.
Maintenance plan
 A document that outlines the management and technical
procedure to be employed to maintain an item; usually describes
facilities, tools, schedules, and resources.
Reliability
 The probability that an item will perform its stated function
satisfactorily for the desired period when used per the specified
conditions.
Maintainability
 The probability that a failed item will be restored to adequately
working condition.
Active repair time
 when repair persons are active to effect a repair.
Mean time to repair (MTTR)
 the averge time it takes to repair system( usally technical or
mechanical)
Overhaul
 A comprehensive/complete inspection and restoration of an item
or a piece of equipment to an acceptable level at a durability time or
usage limit.
Quality
 The degree to which an item, function, or process satisfies
requirements of customer and user.
Maintenance person
 An individual who conducts preventive maintenance and responds
to a user’s service call to a repair facility, and performs corrective
maintenance on an item.

Inspection
 The qualitative observation of an item’s performance or condition.
 1.5 Problems in Maintenance

• Lack of management attention to maintenance

• Little participation by accounting in analyzing and reporting costs
• Difficulties in applying quantitative analysis
• Difficulties in obtaining time and cost estimates for maintenance
works
• Difficulties in Measuring performance
 Problems Exist Due To:

• Failure to develop written objectives and policy

• Inadequate budgetary control
• Inadequate control procedures for work order, service requests etc.
• Infrequent use of standards
• Absence of cost reports to aid maintenance planning and control
system
 Maintenance Costs
• Cost to replace or repair
• Losses of output
• Delayed shipment
• Scrap and rework
1.6 Objectives of Maintenance
 To Keep the system operating at design standard at all times;
 To Obtain the longest life and greatest use of the systems facilities
by providing timely repairs;
More over, Maintenance of machinery have the following objectives
 To Reducing downtime.
 To Improving spares stock control.
 To Improving equipment efficiency and reducing scrap rate.
 To Minimising energy usage.
 To Optimising the useful life of equipment.
Objectives of Maintenance

PLANT
M Reducing Breakdowns
Maximising Production
A
I
Reducing Downtime
Minimising Energy Usage N
T
Optimising Useful Life of E Improving Equipment Efficiency
Equipment N
A
Providing Budgetary Control N Improving Inventory Control

C
Optimising Resource Utilisation E Implementing Cost Reduction
 Types of Maintenance 1.7
 Run to Failure Maintenance (RTF)
 Preventive Maintenance (PM)
 Corrective Maintenance (CM)
 Improvement Maintenance (IM)
 Predictive Maintenance (PdM)
 Reliability Centre Maintenance (RCM)
 Total Productive Maintenance (TPM)
 Types of Maintenance
MAINTENANCE

PLANNED MAINTENANCE .1 UNPLANNED MAINTENANCE .2

(REACTIVE)
(PROACTIVE)

EMERGENCY 2.1 BREAKDOWN 2.2

PREVENTIVE
PREDECTIVE IMPROVEMENT CORRECTIVE
MAINTENANCE MAINTENANCE
MAINTENANCE MAINTENANCE

STATISTICAL - CONDITION - ENGINEERIN

DESIGN - DEFERRED REMEDIAL
BASED BASED G SERVICES
OUT
Shutdown Maintenance

RUNNING ROUT OPPORT SHUTDOWN SHUTDOWN SHUTDOWN

WINDOW PREVENTIVE IMPROVEMENT CORRECTIVE
INE U-NITY
1. Run to Failure Maintenance (RTF)

 It is the oldest type of maintenance and it required that repair after the
occurrence of a failure

 To bring this machine to at least its minimum acceptable condition.

Types Of Run to Failure Maintenance (RTF)

1.1 Emergency maintenance:

 It is carried out as fast as possible in order to bring a failed machine to a

safe and operationally efficient condition.

1.2. Breakdown maintenance

 It is performed after the occurrence of an advanced considered failure

for which advanced provision has been made.
 Run to Failure Maintenance (RTF)

Advantages of RTF Disadvantages of RTF

 Priority of equipment failure is too  Unpredictable

low  Costly.
 Minimal planning  Inventory costs.
 Easy to understand
How to implement run to failure maintenance

This strategy can be adequately managed from memory.

 Other tools can also be used, including paper-based systems,

spreadsheets,computerized maintenance management system
(CMMS) encourge the automation of maintenance) and EAM
(enterprise assest managment focus the over all performance of
assets) systems.

 If an entire facility is working on a run to failure strategy

 Then CMMS and EAM systems will provide much more functionality
than required.
2. Preventive Maintenance (PM)

 It is a set of activities that are performed on plant equipment,

machinery, and systems before the occurrence of a failure

 That is, in order to protect them and to prevent or eliminate any

degradation (humiliation) in their operating conditions.

 The maintenance carried out at predetermined intervals or according

to prescribed(settled) criteria, and

 Intended to reduce the probability of failure or the degradation of

the functioning and the effects limited.
Advantages and Dis-Advantages Preventive Maintenance (PM)

Advantages Dis Advantages

 More money upfront-
 Less risk factor
 Over maintenance
 Follows a schedule  More workers
 Longer equipment/building
life

 Less energy wasting

 Less break
 Element of Preventive Maintenance
There are seven major elements of preventive maintenance which a maintenance
engineer must be conversant with and these are listed below

TESTING:

 There is need to periodically test equipment or machine to determine whether

there is a need for servicing.

SERVICING:

 It is recommended that equipment be periodically lubricated, cleaned and charged

to keep it in top working condition even without any suspicion for breakdown.

CALIBRATION:

 This implies the detection and adjustment of any changes in the accuracy of the
parameters of the system under comparison to the established standard value.
INSPECTION:

 Periodically, equipment must be inspected to discover whether there is need

for servicing or not by comparing their electrical, mechanical and physical
states to the established standards.

ADJUSTMENT:

 This refers to making necessary modification to any slip up slip down

components to ensure better performance.

ALIGNMENT:

 This involves making necessary changes to a device's indicated variable to

ensure better performance.

INSTALLATION:

 Periodically, install items undergoing wear degradation to keep the specified

The Six Principles of Painless Preventive Maintenance

Principle 1: Clear Division of Responsibilities

Principle 2: Focus on Critical Assets First

Principle 3: Set Standards and Track Exceptions

Principle 4: Invite Your Vendors In

Principle 5: Don't Tie Your Field Teams to a Desk

Principle 6: Keep it Simple

 Types Preventive Maintenance (PM)
Researchers subdivided preventive maintenance into different kinds
according to the nature of its activities:

2.1 Routine maintenance

 Maintenance activities that are repetitive and periodic in nature

Example such as lubrication, cleaning, and small adjustment.

2.2 Running maintenance

 Maintenance activities that are carried out while the machine or

equipment is running.

 It represent those activities that are performed before the actual

preventive maintenance activities take place.
2.3 Opportunity maintenance

 Maintenance activities that are performed on a machine when an

unplanned opportunity exists during the period of performing
planned maintenance activities to other machines or facilities.

2.4 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.

2.5 Shutdown preventive maintenance:

 which is a set of preventive maintenance activities that are carried out

when the production line is in total stoppage situation.
3.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.

Note : there are three type of corrective maintenance

1. Remedial maintenance

2. Deferred(postponed) maintenance

3. Shutdown corrective maintenance

Type of Corrective Maintenance (CM)

3.1 Remedial maintenance

 It is a set of activities that performed to eliminate the source of failure

without interrupting the continuity of the production process.
3.2 Deferred (postponed) maintenance

 It is set of corrective maintenance activities that are not immediately

initiated after the occurrence of a failure
3.3 Shutdown corrective maintenance
 It 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
The way to perform corrective maintenance activities is by conducting
four important steps:

 Fault detection

 Fault isolation

 Fault elimination. and

 Verification of fault elimination.

Note: 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, and

the required labour skills, specific tools, parts and equipment.

3. Proper repair procedures.

4. Adequate time to repair.

5. Verification of repair.
 4 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

2. Engineering services

3. Shutdown improvement maintenance

4.1 Design-out maintenance

 It simplify maintenance tasks, or raise machine performance from the

maintenance point of view by redesigning those machines and facilities

4.2. Engineering services

which includes:

 Construction and construction modification,

 Removal and installation

 Rearrangement of facilities.

4.3. Shutdown improvement maintenance

 which is a set of improvement maintenance activities that are performed

while the production line is in a complete stoppage situation.
5.Predictive Maintenance (PDM)
 Predictive maintenance is a set of activities that detect(find) changes
in the physical condition of equipment.

 It is classified into two kinds according to the methods of detecting

the signs of failure:
1. Condition-based predictive maintenance
2. Statistical-based predictive maintenance
5.1 Condition-based predictive maintenance

 It depends on continuous or periodic condition monitoring

equipment to detect the signs of failure.

5.2. Statistical-based predictive maintenance

 It depends on statistical data from the particular recording of the

stoppages of the in-plant items and components in order to develop
models for predicting failures.
 6. Reliability centered maintenance (RCM)

 Reliability centered maintenance (RCM) is a process to ensure that

systems continue to do what their users require in their present
operating context.
 To increase in cost effectiveness, reliability, machine uptime, and a
greater understanding of the level of risk that the organization is
managing.
7. Total productive maintenance (TPM)
 TPM also focuses on the total Participation of individuals from top
management to shop floor (lower employees).
 It focuses on keeping all equipment in top working condition to
avoid breakdowns and delays in manufacturing processes.
 It is a system of maintaining and improving the integrity of
production and quality systems.
 It compile with all the machines, equipment, processes, and
employees that add business value to an organization.
The Main objectives of TPM
 To increase the productivity of plant and equipment with a modest
investment in maintenance.
 To Enhance the volume of the production, employee morale and job
satisfaction
 To increase the Overall Equipment Effectiveness (OEE) of plant
equipment.
 OEE has three factors which are multiplied to give one measure
called Overall Equipment Effectiveness
 OEE=Performance x Availability x Quality
 The Eight pillars of TPM

• Autonomous(indpendent) Maintenance

• Focused Improvement

• Planned Maintenance

• Quality management

• Early/equipment management

• Education and Training

• Safety Health Environment

• Administrative & office TPM

Basic steps for implementation of TPM
- Initial evaluation of TPM level,

- Introductory Education and Advertising (IEP) for TPM,

- Formation of TPM committee,

- Development of master plan for TPM implementation,

- Stage by stage training to the employees and stakeholders

- Implementation preparation process, and

- Establishing the TPM policies and goals and development of a road

map for TPM implementation.
Difficulty of Maintenance of Machinery

 The repair cost

 Environmental impact

 Safety and quality of a product or a service

 8. Maintenance model (HYPOTHESIS OR THEORY )

8.1 Corrective model (HYPOTHESIS OR THEORY )

This is the most basic model, and includes,

 In addition to visual inspections and lubrication mentioned

previously, the arising breakdowns repair.

 It is applied to equipment's with the lowest level of criticality, whose

faults are not a problem, economically or technically.

 8.2 CONDITIONAL
MODEL(HYPOTHESIS OR THEORY )
 This model carries out a series of tests that will determine a

subsequent (consequent) action.

 If after testing that discovered an inconsistency, it will schedule an

intervention;

 On the contrary, if everything is correct, it will not act on the

equipment.

 This maintenance model is valid in equipment not to very used, or

 For equipment that despite being important in the production system

the probability of failure is low.

8.3 SYSTEMATIC
MODEL(HYPOTHESIS OR THEORY )
This model includes:

 It is a set of tasks it will perform no matter what is the condition of

the equipment.

 It will perform some measurements and tests to decide whether to

carry out other tasks of greater magnitude, and

 Finally, it will repair faults that arise.

Other examples:

The landing gear of an aircraft

The engine of an aircraft

 8.4 HIGH AVAILABILITY MAINTENANCE MODEL (HYPOTHESIS OR THEORY )

 It is the most demanding and exhaustive model

 It is applied to that equipment that under no circumstances may

suffer a breakdown or malfunction.

 These are equipment's that required very high levels of availability,

above 90%.

 The reason for such high level of availability is generally high cost
in production due to a fault.

 With a demand so high, there is no time to stop the equipment if

the maintenance requires it (corrective, preventive, systematic).
1.8 Elements of maintenance
• Broadly speaking, the elements in a maintenance
technology can be classified as: attendance,
servicing and repair.
1. Attendance (Operation): Attendance is the
right way 0f avoiding mal-operation which
influences the damages and indirectly the
maintenance. The fundamentals for the use of
any technical means of production are:
Cont..
The fundamentals for the use of any technical
means of production are:
• proper use of operating instruction provided in
operators manuals
• proper use of service instructions given in
service instructions
• Following proper maintenance procedures and
as outlined in maintenance manuals.
2. Service:
• Servicing of a machine is important in decelerating
wear or damage of machine parts. important
measures to be taken in servicing are cleaning,
lubricating and adjusting.
3. Repair
• Repair is the totality of measures of restoration with
the aim of determined final state, or quality, or
condition of equipment. Classification of repair
activities is based on the following considerations.
a) time related to breakdown b) number of
elements involved in the repair task, c) nature
of repair activity, d) territorial or labour
involved.
1.9 decision making
• A decision problem exists when:
• there is a desired objective,
• at least two courses of action are available,
• there is uncertainty as to which course is the
best, and
• external factors are present which can affect the
outcome and which are outside the control of the
decision maker.
Cont…

• Influencing factors in decision making and in

identification of the most suitable action are the
following:
• Cause of failure
• Failure incidence with respect to time
• Costs of maintenance or re-design
• Maintainability
 Individual Assignment (20%)

• Explain the different types of maintenance, their

main objectives, advantages and disadvantages of
those subtypes.
• Maintenance models
• Elements of maintenance
• Decision making