(1)

a. State the importance of maintenance in different engineering sectors as per mechanical engineering
(Ex. thermal power plant, aluminium plant and automobile industry for ME and steel production plant
for MME etc.).
Ans;
Thermal power plant: Maintenance is essential to ensure the reliable operation of thermal power plants,
which generate electricity using heat from burning fossil fuels. Preventive maintenance can help to prevent
breakdowns and extend the life of equipment.
Aluminium plant: Aluminium plants use a variety of complex machinery and equipment to smelt
aluminium from bauxite ore.
Automobile industry: Automobiles are complex machines with a variety of moving parts.
b. What is “maintenance”? How it differs from repair? Enlist 10 Maintenance Functions.
Ans;
Maintenance is the process of keeping equipment and assets in good working order. It can be preventive,
corrective, or predictive. The key difference between maintenance and repair is that maintenance is
proactive, while repair is reactive.

 Inspection: Examining equipment and assets for signs of wear and tear, damage, or defects.
 Cleaning: Removing dirt, dust, and other contaminants from equipment and assets.
 Lubrication: Applying lubricants to moving parts to reduce friction and wear.
 Adjustment: Making minor adjustments to equipment and assets to ensure proper operation.
 Replacing worn parts: Replacing parts that have become worn or damaged.
 Repairing damaged components: Fixing components that have become damaged.
 Troubleshooting electrical problems: Identifying and fixing electrical problems.
 Calibrating equipment: Adjusting equipment to ensure that it is operating within specified
tolerances.
 Overhauling equipment: Disassembling, inspecting, and rebuilding equipment to extend its life.
 Reconditioning assets: Cleaning, inspecting, and repairing assets to restore them to their original
condition.
c. Enlist several objectives of maintenance.
Ans;
Several objectives of maintenance:

 To prevent equipment failure and downtime.

 To extend the life of equipment and assets.
 To improve the reliability of equipment and assets.
 To improve the safety of workers and the public.
 To reduce environmental impact.
 To comply with regulations.
 To improve product quality.
 To improve customer satisfaction.
 To reduce costs.
 To improve efficiency.
 To maximize asset utilization.
d. What is Maintenance Management? Enlist 6 functions of maintenance management.

Ans;

Maintenance management is the process of planning, organizing, and controlling the maintenance of
equipment and assets. It is a systematic approach to ensuring that equipment and assets are maintained in
a safe and reliable condition.

The 6 functions of maintenance management:

 Planning: This involves identifying the maintenance needs of equipment and assets, and developing
a plan to meet those needs.
 Organizing: This involves assigning tasks to personnel, and ensuring that the necessary resources
are available.
 Controlling: This involves monitoring the progress of maintenance activities, and making
adjustments as needed.
 Scheduling: This involves determining when maintenance activities will be performed.
 Budgeting: This involves estimating the cost of maintenance activities, and allocating the necessary
resources.
 Reporting: This involves tracking and reporting on the performance of the maintenance program.

e. How will you select a maintenance strategy?

Ans;

To select a maintenance strategy, I would consider the following factors:

 Criticality of the equipment: How important is the equipment to the business? If the equipment is
critical to the business, then it is important to implement a maintenance strategy that will prevent
failures and downtime.
 Cost of equipment failure: What is the cost of equipment failure in terms of lost production, lost
sales, and repair costs? If the cost of equipment failure is high, then it is important to implement a
maintenance strategy that will reduce the risk of failure.
 Ease of monitoring the equipment: How easy is it to monitor the equipment for signs of wear and
tear or potential problems? If the equipment is difficult to monitor, then it may be necessary to
implement a maintenance strategy that is more preventive in nature.
 Availability of maintenance resources: Does the business have the necessary maintenance
resources, such as skilled technicians and spare parts, to implement the selected maintenance
strategy?
 Budgetary constraints: What is the business's budget for maintenance? The selected maintenance
strategy should be within the business's budget.

f. Differentiate between planned and unplanned maintenance.

Ans;

Planned maintenance is maintenance that is performed on a scheduled basis, typically according to a

maintenance plan. Planned maintenance can include preventive maintenance, predictive maintenance,
and corrective maintenance.
Unplanned maintenance is maintenance that is performed in response to an unexpected equipment
failure. Unplanned maintenance can include emergency repairs and corrective maintenance that is not
scheduled in advance.

g. What is Opportunistic Maintenance and why it is called so? Give one example.
Ans;

Opportunistic maintenance is a type of maintenance that is performed when an equipment shutdown

or other unplanned event occurs. This allows for preventive maintenance or corrective maintenance to
be performed on the equipment while it is already unavailable.
Opportunistic maintenance is called so because it takes advantage of unplanned events to perform
maintenance tasks that would not otherwise be possible. This can be a cost-effective way to maintain
equipment, as it can save businesses the cost of scheduling a separate maintenance shutdown.
Here is an example of opportunistic maintenance:
A power plant experiences an unplanned shutdown due to a problem with one of its generators.

h. Give two examples of Breakdown maintenance. State its limitations.

Ans;

Two examples of breakdown maintenance:

 Emergency repairs: These are repairs that must be performed immediately to prevent a safety
hazard or to restore equipment to operation. For example, if a power plant generator fails,
emergency repairs must be performed to restore power to the grid.
 Corrective maintenance: These are repairs that are performed to fix equipment that has already
failed. For example, if a machine breaks down on the production line, corrective maintenance must
be performed to get the machine back up and running.

Limitations of breakdown maintenance:

1. Unscheduled downtime
2. Increased repair costs
3. Reduced equipment life
4. Safety hazards

i. Differentiate between Planned and unplanned breakdown maintenance.

Ans;

Planned breakdown maintenance (also known as run-to-failure maintenance) is a maintenance strategy in

which equipment is operated until it fails, and then maintenance is performed to repair the equipment and
restore it to operation.

Unplanned breakdown maintenance is a maintenance strategy in which maintenance is performed on

equipment after it has failed.

j. What do you mean by Design-out maintenance? Give one example.

Ans;
Design-out maintenance is a maintenance strategy that aims to prevent equipment failure by eliminating
the root causes of failure. This can be done by designing equipment with high reliability and durability, and
by using materials and components that are less likely to fail.
One example of design-out maintenance is the use of sealed bearings in rotating equipment. Sealed
bearings are designed to prevent contaminants from entering the bearing and causing wear and tear. This
can significantly extend the life of the bearing and reduce the need for maintenance.
k. Differentiate between primary signals and secondary signals emanating from machines.
Ans;

Primary signals are signals that are emitted directly from the machine itself. They can be physical signals,
such as vibration, noise, or temperature, or they can be electrical signals, such as current or voltage.

Secondary signals are signals that are generated by sensors or other devices that are connected to the
machine. They can be used to monitor the machine's condition and to predict failures.

l. What is Condition-based maintenance? Explain with example. Enlist various condition monitoring
techniques.

Ans;

Condition-based maintenance (CBM) is a proactive maintenance strategy that uses data and analytics to
predict when equipment is likely to fail. This allows maintenance to be performed before a failure occurs,
which can save businesses money and improve uptime.
Example of CBM:
A power plant uses vibration sensors to monitor the condition of its rotating equipment. If the vibration
level of a generator shaft increases above a certain threshold, an alarm is triggered and maintenance
personnel are notified. Maintenance personnel can then take corrective action to prevent the generator
from failing.

Various condition monitoring techniques:

1. Vibration analysis
2. Oil analysis
3. Thermal imaging
4. Ultrasonic testing
5. Non-destructive testing (NDT)

m. How Condition Based Maintenance differs from Predictive Maintenance?

Ans;
Condition-based maintenance (CBM) is a proactive maintenance strategy that uses data and analytics to
predict when equipment is likely to fail. This allows maintenance to be performed before a failure occurs,
which can save businesses money and improve uptime.
Predictive maintenance (PdM) is a more advanced form of CBM that uses machine learning and artificial
intelligence to predict when equipment is likely to fail with greater accuracy. This allows businesses to
schedule maintenance more efficiently and to reduce the risk of unplanned downtime.
n. How predictive maintenance differs from preventive maintenance. What are its drawbacks?

Ans;

Predictive maintenance (PdM) is a proactive maintenance strategy that uses machine learning and
artificial intelligence to predict when equipment is likely to fail with greater accuracy. This allows
businesses to schedule maintenance more efficiently and to reduce the risk of unplanned downtime.

Preventive maintenance (PM) is a reactive maintenance strategy that involves performing maintenance
tasks on equipment at predetermined intervals, regardless of the condition of the equipment.

Drawbacks of PdM:

1. Initial investment
2. Data collection
3. Model accuracy
4. Complexity

o. What is the difference between maintenance planning and maintenance scheduling.

Ans;

Maintenance planning is the process of determining what maintenance tasks need to be performed, when
they need to be performed, and who will perform them.

Maintenance scheduling is the process of assigning specific dates and times to maintenance tasks.

p. Name various facets of Maintenance planning. Enlist the steps involved maintenance planning.

Ans;

Facets of maintenance planning:

1. Asset identification
2. Asset condition assessment
3. Maintenance task identification
4. Maintenance task prioritization
5. Maintenance schedule development
6. Task assignment
7. Maintenance cost estimation
8. Maintenance documentation

Steps involved in maintenance planning:

1. Asset inventory: Create a list of all of the assets that need to be maintained.
2. Condition assessment: Inspect each asset to assess its condition.
3. Task identification: Identify the specific maintenance tasks that need to be performed on each
asset.
4. Task prioritization: Prioritize the maintenance tasks based on risk and importance.
5. Schedule development: Develop a schedule for performing the maintenance tasks.
6. Task assignment: Assign the maintenance tasks to technicians.
7. Cost estimation: Estimate the cost of performing the maintenance tasks.
8. Documentation: Document the maintenance plan and schedules.
q. Differentiate between short term and long-term maintenance planning.

Ans;

Short-term maintenance planning is the process of developing a schedule for performing maintenance
tasks within the next few weeks or months. This type of planning is typically used to address immediate
maintenance needs and to ensure that critical equipment is maintained on a regular basis.

Long-term maintenance planning is the process of developing a schedule for performing maintenance
tasks over the next year or more. This type of planning is typically used to address larger maintenance
projects, such as overhauls and replacements.

r. State the importance of “maintenance scheduling”.

Ans;

Maintenance scheduling is the process of assigning specific dates and times to maintenance tasks. It is an
important part of any maintenance program, as it helps to ensure that the right maintenance tasks are
performed at the right time.

Here are some of the key benefits of maintenance scheduling:

 Reduces the risk of equipment failures

 Improves uptime
 Saves money
 Improves communication and coordination
 Provides a basis for performance measurement

s. Differentiate between short term and long-term maintenance planning.

Ans;

Short-term maintenance planning is the process of developing a schedule for performing maintenance
tasks within the next few weeks or months. This type of planning is typically used to address immediate
maintenance needs and to ensure that critical equipment is maintained on a regular basis.

Long-term maintenance planning is the process of developing a schedule for performing maintenance
tasks over the next year or more. This type of planning is typically used to address larger maintenance
projects, such as overhauls and replacements.

t. What are the pre-requisites of maintenance scheduler.

Ans;

Prerequisites for a maintenance scheduler

1. Technical knowledge
2. Scheduling skills
3. Communication and coordination skills
4. Data analysis skills
5. Problem-solving skills
u. Differentiate between PERT and CPM in context to maintenance engineering.
Ans;

PERT (Program Evaluation and Review Technique) and CPM (Critical Path Method) are both project
management tools that can be used to schedule maintenance tasks.

PERT is a probabilistic method that uses three time estimates for each task: optimistic, pessimistic, and
most likely. This allows for the uncertainty in task completion times to be accounted for.

CPM is a deterministic method that uses a single time estimate for each task. This makes it simpler to use
than PERT, but it does not account for uncertainty in task completion times.

v. State various modes of failure. List out 10 failure detection methods.

Ans;

Various modes of failure:

1. Breakdown: The complete failure of a component or system.

2. Malfunction: A partial failure of a component or system that results in reduced performance or
functionality.
3. Leak: The escape of fluid or gas from a component or system.
4. Deformation: A change in the shape or size of a component or system.
5. Corrosion: The deterioration of a material due to chemical reaction with its environment.
6. Fatigue: The weakening of a material due to repeated loading and unloading.
7. Erosion: The gradual removal of material from a surface due to mechanical action.
8. Wear: The gradual loss of material from a surface due to friction.
9. Overheating: The excessive rise in temperature of a component or system.
10. Electrical failure: A malfunction of an electrical component or system.

10 failure detection methods:

1. Visual inspection
2. Mechanical vibration monitoring
3. Oil analysis
4. Thermal imaging
5. Electrical resistance testing
6. Ultrasonic testing
7. Magnetic particle testing
8. Acoustic emission testing
9. Eddy current testing
10. Condition monitoring software

w. Define 4 maintenance performance measuring indices.

Ans;
Availability: The percentage of time that equipment is available for use.
Reliability: The probability that equipment will perform its intended function without failure for a specified period of
time.
Maintainability: The ease with which equipment can be maintained.
Cost-effectiveness: The relationship between the cost of maintenance and the benefits that it provides.
x. What do you mean by Equipment downtime? How it is expressed.
Ans;

Equipment downtime is the period of time during which equipment is unavailable for use due to a failure
or other problem. Downtime can be caused by a variety of factors, including:

 Breakdowns: Complete failures of equipment components.

 Malfunctions: Partial failures of equipment components that result in reduced performance or
functionality.
 Maintenance: Planned shutdowns of equipment for preventive or corrective maintenance.
 Accidents: Unexpected events that damage equipment.

y. What is Pareto Analysis? How it helps in root cause analysis?

Ans;

Pareto analysis is a technique used to identify the most important causes of a problem. It is based on the
Pareto principle, which states that for many events, roughly 80% of the effects come from 20% of the
causes.

Pareto analysis can help in root cause analysis by:

 Focusing attention on the most important causes of the problem.

 Identifying areas where corrective action is most needed.
 Prioritizing maintenance and improvement projects.

z. Why record keeping is important in industrial management?

Ans;
Record keeping is important in industrial management because it provides a valuable source of data that
can be used to improve operations, make better decisions, and track progress over time.
2. What is “Maintenance”? Name various types of maintenance systems. How will you select a
maintenance strategy?
Ans;

Maintenance is the process of keeping equipment in good working order. It can be preventive, corrective,
or predictive.

Preventive maintenance is performed on a regular basis to prevent equipment failures. This can involve
tasks such as changing oil and filters, lubricating bearings, and inspecting components for wear and tear.
Corrective maintenance is performed to repair equipment that has failed. This can involve tasks such as
replacing broken components, welding cracks, and overhauling engines.
Predictive maintenance is performed to identify potential failures before they occur. This can involve using
condition monitoring techniques such as vibration analysis, oil analysis, and thermal imaging.

There are four main types of maintenance systems:

 Time-based maintenance: This system involves performing maintenance tasks at predetermined

intervals, regardless of the condition of the equipment.
 Condition-based maintenance: This system involves performing maintenance tasks based on the
condition of the equipment, as determined by condition monitoring techniques.
 Failure-based maintenance: This system involves waiting until equipment fails before performing
maintenance.
 Proactive maintenance: This system involves taking a proactive approach to maintenance by
identifying and addressing potential problems before they cause equipment failures.

Here are some factors to consider when selecting a maintenance strategy:

 Criticality of the equipment: The more critical the equipment, the more important it is to
implement a proactive maintenance strategy.
 Cost of maintenance: Preventive maintenance is typically more expensive than corrective
maintenance, but it can save money in the long run by preventing equipment failures.
 Availability of spare parts: If spare parts are not readily available, then a time-based maintenance
strategy may be more appropriate.

3. Describe a general model of a maintenance system. What are the challenges faced by the maintenance
function of a modern industry.
Ans;

General model of a maintenance system:

A maintenance system can be broadly divided into the following components:

 Asset management: This involves identifying and tracking all of the assets that need to be
maintained.
 Condition monitoring: This involves using sensors and other monitoring systems to collect data on
the condition of the assets.
 Decision support: This involves using the data collected from condition monitoring to make
decisions about maintenance tasks.
 Maintenance execution: This involves performing the maintenance tasks that have been decided
upon.
Challenges faced by the maintenance function of a modern industry:

 Complexity: Modern industrial equipment is becoming increasingly complex, making it more

difficult to maintain.
 Asset obsolescence: Equipment is becoming obsolete more quickly, which can make it difficult to
find spare parts and qualified technicians.
 Data overload: Modern maintenance systems generate a large amount of data, which can be
difficult to manage and analyze.
 Cost: The cost of maintenance is increasing, due to the complexity of equipment and the need for
more specialized skills.
 Sustainability: Businesses are increasingly under pressure to reduce their environmental impact,
which can make it difficult to balance the need for maintenance with the need to reduce waste.

4. Describe the objectives and functions of maintenance management.

Ans;

Objectives of maintenance management:

1. To keep equipment in good working order and prevent unplanned downtime.

2. To improve the reliability and lifespan of equipment.
3. To reduce maintenance costs.
4. To improve safety and environmental performance.
5. To support the overall business goals.

Functions of maintenance management:

 Asset management: This involves identifying and tracking all of the assets that need to be
maintained.
 Condition monitoring: This involves using sensors and other monitoring systems to collect data on
the condition of the assets.
 Maintenance planning and scheduling: This involves developing and implementing plans for
performing maintenance tasks.
 Maintenance execution: This involves performing the maintenance tasks that have been planned
and scheduled.
 Maintenance budgeting and cost control: This involves managing the budget for maintenance
activities and ensuring that costs are controlled.
 Maintenance quality control and assurance: This involves ensuring that maintenance tasks are
performed correctly and that equipment is returned to service in a safe and reliable condition.
 Maintenance performance measurement and improvement: This involves collecting data on
maintenance performance and using this data to identify areas for improvement.

5. Explain “Corrective Maintenance”. Elucidate the steps involved. State difference between “Breakdown
maintenance” and “Corrective maintenance”.
Ans;

Corrective maintenance is a type of maintenance that is performed to repair equipment that has failed. It
is typically reactive in nature, meaning that it is performed after a failure has occurred.
Steps involved in corrective maintenance:

1. Identify the failure: The first step is to identify the cause of the failure. This can be done by
inspecting the failed equipment and looking for signs of damage or wear and tear.
2. Isolate the failure: Once the cause of the failure has been identified, the failed component or
system must be isolated from the rest of the equipment. This may involve shutting down the
equipment or disconnecting the failed component.
3. Repair the failure: The failed component or system must then be repaired or replaced. This may
involve using spare parts or performing a complete overhaul.
4. Test the repair: Once the repair has been completed, the equipment must be tested to ensure that
it is operating properly.
5. Return the equipment to service: Once the equipment has been tested and verified to be
operating properly, it can be returned to service.

Difference between breakdown maintenance and corrective maintenance:

 Breakdown maintenance: Breakdown maintenance is performed on equipment that has failed and
is no longer operating. It is a reactive type of maintenance that is typically performed after a failure
has occurred.
 Corrective maintenance: Corrective maintenance is performed to repair equipment that has failed.
It is also a reactive type of maintenance, but it is typically performed more quickly than breakdown
maintenance.

6. What are preventive maintenance and predictive maintenance. State their advantages and limitations.
Ans;

Preventive maintenance is a type of maintenance that is performed on equipment at regular intervals to

prevent failures. It is a proactive type of maintenance that is typically performed before a failure has
occurred.

Advantages

 Reduced downtime: Preventive maintenance can help to reduce downtime by preventing failures
from occurring.
 Improved reliability: Preventive maintenance can help to improve the reliability of equipment by
identifying and correcting potential problems before they cause a failure.
 Extended equipment lifespan: Preventive maintenance can help to extend the lifespan of
equipment by preventing premature wear and tear.
 Reduced maintenance costs: Preventive maintenance can help to reduce maintenance costs by
preventing major failures that would require expensive repairs.

Limitations

 Cost: Preventive maintenance can be expensive, especially if it requires equipment to be shut down
for extended periods of time.
 Inaccuracy: Preventive maintenance schedules are based on historical data, which may not be
accurate for all equipment.
 Over-maintenance: If preventive maintenance schedules are too aggressive, equipment may be
over-maintained, which can lead to unnecessary costs and downtime.
Predictive maintenance is a type of maintenance that uses data to predict when equipment is likely to fail.
It is also a proactive type of maintenance, but it is typically more sophisticated than preventive
maintenance.

Advantages

 More accurate predictions: Predictive maintenance can use data to make more accurate
predictions about when equipment is likely to fail. This can help to reduce unnecessary
maintenance and downtime.
 Reduced maintenance costs: Predictive maintenance can help to reduce maintenance costs by
preventing major failures that would require expensive repairs.
 Improved safety: Predictive maintenance can help to improve safety by identifying potential
problems before they cause a failure.

Limitations

 Cost: Predictive maintenance can be expensive, especially if it requires sophisticated data collection
and analysis systems.
 Complexity: Predictive maintenance can be complex to implement and manage.
 Accuracy: Predictive maintenance systems are only as accurate as the data that they are trained on.
If the data is inaccurate, the predictions will be inaccurate.

7. Illustrate difference between “preventive maintenance” and “predictive maintenance” through flow
charts.
Ans;
(Leave 2 pages)

8. Explain condition-based maintenance system (CBM). Describe the methodology adopted for CBM with
example. State their advantages and limitations.
Ans;

Condition-based maintenance (CBM) is a proactive maintenance strategy that uses data to predict when
equipment is likely to fail. CBM systems typically use sensors to collect data on the condition of equipment,
such as vibration, temperature, and oil analysis.

Methodology adopted for CBM:

 Identify critical equipment

 Select condition indicators
 Develop thresholds
 Collect data
 Analyse data
 Take corrective action
Example of CBM:

A manufacturing plant uses a CBM system to monitor the vibration of its rotating shafts. The plant has set a
threshold for vibration. If the vibration of a shaft exceeds the threshold, this indicates that a problem is
developing and the shaft needs to be inspected.

Advantages of CBM:

 Reduced downtime: CBM can help to reduce downtime by preventing failures from occurring.
 Improved reliability: CBM can help to improve the reliability of equipment by identifying and
correcting potential problems before they cause a failure.
 Extended equipment lifespan: CBM can help to extend the lifespan of equipment by preventing
premature wear and tear.
 Reduced maintenance costs: CBM can help to reduce maintenance costs by preventing major
failures that would require expensive repairs.

Limitations of CBM:

 Cost: CBM systems can be expensive to implement and maintain.

 Complexity: CBM systems can be complex to implement and manage.
 Accuracy: CBM systems are only as accurate as the data that they are trained on. If the data is
inaccurate, the predictions will be inaccurate.

9. Explain the maintenance planning in detail. State its importance. List out the sequencing of activities
carried out in maintenance planning.
Ans;

Maintenance planning is the process of developing and implementing a plan to keep equipment in good
working order and prevent unplanned downtime. It involves identifying the critical equipment, developing
maintenance schedules, and ensuring that the necessary resources are available to perform the required
maintenance tasks.

Importance of maintenance planning:

 Reduced downtime: Maintenance planning can help to reduce downtime by preventing failures
from occurring.
 Improved reliability: Maintenance planning can help to improve the reliability of equipment by
identifying and correcting potential problems before they cause a failure.
 Extended equipment lifespan: Maintenance planning can help to extend the lifespan of equipment
by preventing premature wear and tear.
 Reduced maintenance costs: Maintenance planning can help to reduce maintenance costs by
preventing major failures that would require expensive repairs.
 Improved safety: Maintenance planning can help to improve safety by identifying and correcting
potential safety hazards.
Sequencing of activities carried out in maintenance planning:

1. Asset identification
2. Asset criticality assessment
3. Maintenance task identification
4. Maintenance task scheduling
5. Maintenance task prioritization
6. Maintenance resource allocation
7. Maintenance task execution
8. Maintenance task documentation

10. Explain the maintenance scheduling in detail. Give details about different scheduling techniques and
principles used in industries.
Ans;

Maintenance scheduling is the process of determining when and how maintenance tasks should be
performed. It is an important part of maintenance planning and management.

Different scheduling techniques and principles used in industries:

 Time-based scheduling: Time-based scheduling involves scheduling maintenance tasks at regular

intervals, regardless of the condition of the equipment.
 Condition-based scheduling: Condition-based scheduling involves scheduling maintenance tasks
based on the condition of the equipment. This is a more sophisticated type of scheduling than time-
based scheduling, but it can be more effective at reducing downtime and improving reliability.
 Risk-based scheduling: Risk-based scheduling involves scheduling maintenance tasks based on the
risk of failure. This type of scheduling is particularly useful for critical equipment.
 Capacity-based scheduling: Capacity-based scheduling involves scheduling maintenance tasks
based on the availability of maintenance resources. This type of scheduling is important for
businesses that have limited maintenance resources.

Other scheduling techniques and principles:

 Critical path method (CPM): CPM is a scheduling technique that is used to identify the critical path
of a project. The critical path is the sequence of tasks that must be completed on time in order to
complete the project on time.
 Earned value management (EVM): EVM is a scheduling technique that is used to track the progress
of a project and identify any potential problems.
 Just-in-time (JIT) maintenance: JIT maintenance involves scheduling maintenance tasks as close to
the time of need as possible. This type of scheduling can help to reduce inventory costs and
improve efficiency.

Scheduling principles:

 Prioritization: Maintenance tasks should be prioritized based on their criticality and urgency.
 Availability: Maintenance tasks should be scheduled in a way that minimizes disruption to
operations.
 Capacity: Maintenance tasks should be scheduled based on the availability of maintenance
resources.
 Flexibility: Maintenance schedules should be flexible enough to accommodate unexpected
changes.
11. Explain “Gantt Chart and Bar Chart” and “PERT and CPM” in context to maintenance engineering.
State their advantages and limitations.

Ans;

Gantt charts and bar charts are simple scheduling tools that can be used to visualize and track the
progress of maintenance tasks. They are typically used for time-based scheduling, but they can also be
used for condition-based scheduling if the maintenance tasks are scheduled at regular intervals based on
the condition of the equipment.

Advantages of Gantt charts and bar charts:

 Easy to use: Gantt charts and bar charts are relatively easy to understand and use.
 Flexible: Gantt charts and bar charts can be used to schedule a variety of tasks, regardless of their
complexity.
 Visual: Gantt charts and bar charts provide a visual representation of the maintenance schedule,
which can help to identify potential problems and make adjustments as needed.

Limitations of Gantt charts and bar charts:

 Not suitable for complex tasks: Gantt charts and bar charts can be difficult to use for complex tasks
with many dependencies.
 Not accurate: Gantt charts and bar charts are based on estimates, so they may not be accurate in
predicting the actual time required to complete tasks.

PERT and CPM are more sophisticated scheduling techniques that can be used to schedule complex
maintenance tasks with many dependencies. PERT stands for Program Evaluation and Review Technique,
while CPM stands for Critical Path Method.

Advantages of PERT and CPM:

 Accurate: PERT and CPM are based on probabilistic analysis, so they can provide more accurate
predictions of the time required to complete tasks.
 Suitable for complex tasks: PERT and CPM can be used to schedule complex maintenance tasks
with many dependencies.
 Identifies critical path: PERT and CPM identify the critical path of a project, which is the sequence
of tasks that must be completed on time in order to complete the project on time.

Limitations of PERT and CPM:

 Complex: PERT and CPM can be complex to use and require specialized training.
 Requires accurate data: PERT and CPM require accurate data on task durations and dependencies
in order to provide accurate predictions.

12. Describe Equipment Downtime Analysis. Explain its benefits and challenges. How equipment downtime can be
reduced.

Ans;

Equipment downtime analysis is the process of identifying and understanding the causes of equipment
downtime. It is an important tool for maintenance engineers to use to improve the reliability and
availability of equipment.
Benefits of equipment downtime analysis:

1. Reduced downtime
2. Improved reliability
3. Increased productivity
4. Reduced costs

Challenges of equipment downtime analysis:

 Data collection: Collecting data on equipment downtime can be challenging, especially for complex
systems.
 Data analysis: Analyzing data on equipment downtime can be complex and time-consuming.
 Identifying root causes: It can be difficult to identify the root causes of downtime, especially for
complex systems.

How equipment downtime can be reduced:

 Preventive maintenance: Preventive maintenance is one of the most effective ways to reduce
equipment downtime.
 Condition-based maintenance: Condition-based maintenance (CBM) is a proactive maintenance
strategy that uses data to predict when equipment is likely to fail.
 Root cause analysis: By performing root cause analysis on downtime events, maintenance
engineers can identify the underlying causes of downtime and take steps to prevent future
occurrences.
 Improved maintenance planning and scheduling: By using effective maintenance planning and
scheduling techniques, maintenance engineers can ensure that maintenance tasks are performed
efficiently and effectively, which can help to reduce downtime.

13. (Leave 2 pages)

14. What is Root cause analysis (RCA)? Explain basic methods and frames of RCA.

Ans;

Root cause analysis (RCA) is a process of identifying and understanding the underlying causes of a problem
or event. It is a systematic approach to problem-solving that can be used to prevent future occurrences.

Basic methods of RCA:

 Five Whys: The Five Whys method is a simple but effective RCA method. It involves asking the
question "Why?" five times to get to the root cause of a problem.
 Fishbone diagram: The Fishbone diagram, also known as the Ishikawa diagram, is a visual tool that
can be used to identify the root causes of a problem. It is based on the idea that problems are
caused by a combination of factors, which are represented by the bones of the fish.
 Pareto analysis: Pareto analysis is a method for identifying the most important causes of a
problem. It is based on the Pareto principle, which states that 80% of the problems are caused by
20% of the causes.
 Fault tree analysis: Fault tree analysis is a method for identifying the potential causes of a failure. It
is used in safety engineering to identify and mitigate risks.
15. Illustrate:

i. Fault Tree Analysis (FTA),

ii. Failure Mode Effects Analysis (FMEA)
iii. Failure Mode Effects Criticality Analysis (FMECA)

Ans;

Fault Tree Analysis (FTA)

Fault tree analysis (FTA) is a top-down approach to identifying the potential causes of a failure. It is a
graphical method that uses logic gates to show how different causes can combine to lead to a failure.

FTA is typically used to analyze safety-critical systems, such as aircraft and nuclear power plants. It can also
be used to analyze other systems where failures can have serious consequences, such as manufacturing
plants and healthcare facilities.

Failure Mode Effects Analysis (FMEA)

Failure mode effects analysis (FMEA) is a bottom-up approach to identifying the potential consequences of
failures. It is a systematic method for identifying and evaluating potential failures and their effects on a
system.

FMEA is typically used to analyze new products and processes before they are put into production. It can
also be used to analyze existing products and processes to identify potential failures and take steps to
prevent them.

Failure Mode Effects Criticality Analysis (FMECA)

Failure mode effects criticality analysis (FMECA) is an extension of FMEA that includes a risk assessment.
FMECA considers the severity, likelihood, and detectability of each failure mode to determine its criticality.

FMECA is typically used to analyze safety-critical systems. It can also be used to analyze other systems
where failures can have serious consequences.