MAINTENANCE

 Maintenance - is the process of keeping the machine and equipment in good working
condition.
 Equipment maintenance - is a combination of actions carried out to replace, repair, and
service the machineries, components in a manufacturing plant so that it will continue to
operate satisfactorily.
 Failure – is a digress of demands of a certain quality

Problems of Equipment/Plant Breakdown

 Plant breakdown creates problems such as:
1. Loss of production time.
2. Rescheduling of production.
3. Materials wastage (due to sudden stoppage of process damages in process materials).
4. Need for overtimes,
5. Need for work subcontracting.
6. Failure to recover overheads (because of loss in production hours).
7. Temporary work shortages-workers require alternative work.

Costs Associated With Equipment Failure

 These Costs are: -
1. Disrupted production schedules
2. Idle workers
3. Loss of output,
4. Damage to products or other equipment.

Importance of Plant Maintenance

1. Optimizing the usage of plant, machinery and tools.
2. Optimizing the usage of manpower in maintenance.
3. Ensuring smooth production flow.
4. Minimizing the loss of productive time
5. Extending the useful life of the plant, machinery and other facilities
6. Improving reliability, availability and maintainability
7. Minimizing the total maintenance cost
8. Ensuring the safety of personnel through regular inspection and maintenance of facilities

Functions of Equipment/Plant Maintenance

1. Inspection
2. Repair
3. Overhaul
4. Lubrication
5. Salvage

a) Inspection
 Inspection – is the detection of faults before they develop in to breakdown of the equipment.
 Inspection involves periodic checking of machines and equipment to: -
i. Ensure safe and efficient operation,

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 ii. Make certain that equipment requiring work at specified periods receives proper
attention,
iii. Determination of repair feasibility
iv. Control of the quality of work accompanied by maintenance group,
 The initial symptoms of the machine trouble include: - noise, vibration, dirtiness, leak or heat
of the machine.

b) Repair
 Repair – is the process of repairing the component or replacing the item or part by another
item to restore the item in working order.
 This is done when an item or components fails or breakdown.
c) Overhaul
 In overhauling - the machine is stripped and the various parts are cleaned and oiled and
components are replaced.
d) Lubrication
 Lubrication plays a vital role in maintaining the machine accuracy and increasing its life.
 The cleaning and lubrication of the machine is normally done by the operator itself.

e) Salvage
 Any equipment is said to be salvage when it cannot be repaired or cannot be brought to
desired level of performance.
 Salvage item is to be replaced by new one to bring back the system into operation.

Types of Maintenance Practices

1. Corrective maintenance/reactive maintenance/breakdown maintenance
2. Preventive maintenance
3. Planned maintenance
4. Routine maintenance

CORRECTIVE MAINTENANCE
 Corrective Maintenance - is also known as: -
 Reactive Maintenance
 Break Down Maintenance.
Definition
 Corrective Maintenance - is defined as any maintenance performed to return equipment to
proper working order.
 Corrective maintenance - is a maintenance task performed to identify, isolate, and rectify a
fault so that the failed equipment, machine, or system can be restored to an operational
condition.
 It refers to maintenance due to a breakdown of equipment, machine, or system
 It involves all unscheduled actions performed as a result of system or product failure.
 This approach is mainly a response to machine breakdowns.

Causes of Breakdown
1. Failure to replace the worn-out parts
2. Lack of lubrication
3. Neglected cooling system

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 4. Carelessness towards minor repairs - e.g. equipment vibrations, unusual sounds coming
out of the rotating machinery, equipment getting too much heated up, etc.
5. External factors - such as too low or too high line voltage, wrong fuel, etc.

Procedure for Breakdown Maintenance

 It involves the following steps
1. Failure identification,
2. Localization and isolation,
3. Disassembly,
4. Item removal and replacement or repair in place,
5. Reassembly
6. Checkout and condition verification.

Planned Corrective Maintenance

 Planned corrective maintenance – is as a result of a run-to-failure maintenance plan.
 The maintenance team decides that certain equipment will be serviced when it breaks down.
 E.g. replacing a lightbulb once it burns out.

Unplanned Corrective Maintenance

 Unplanned corrective maintenance - is usually the result of an unexpected breakdown.
 An example: a piece of machinery breaking down due to a replacement part failing after
being replaced during a routine PM.
 Corrective maintenance will need to be performed to get the machinery back in working
order.

Corrective Maintenance Workflow

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Overview
 Corrective maintenance is initiated when an additional problem is discovered during a
separate work order.
 For example, during an emergency repair, as part of a routine inspection, or in the process of
conducting preventive maintenance, a technician spots another issue that needs corrected
before other problems occur.
 Upon discovering an additional problem, corrective maintenance is planned and scheduled
for a future time.
 During the execution of corrective maintenance work, the asset is repaired, restored, or
replaced

Work Card
 Work Card – is also referred as: -
 Task Card or
 Job Card.
 A Work Card/Job Card - is a detailed description of work that is performed for a work order.
 Work Card – is a tailored description of a maintenance task prepared from original
documentation by a technical support office to facilitate the correct completion of that task
by those assigned to complete it

History Card
 History card – is a card showing the maintenance of every equipment

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 Name of the piece of equipment:
Label:
Serial number:
Manufacturer:
Manufacturer's contact person + contact
details:
Date of purchase:
Date put into service:
Person responsible for equipment:
Initials of person authorized to use
equipment:
Location of equipment:
Physical condition:
Service provider (for maintenance and
calibration):
Service provider contact person + contact
details:
Frequency of maintenance:

Date: Description of Maintenance Date of Validation Next Remarks:

maintenance: performed validation performed maintenance
by: before put by: planned on
into (date):
service:

Advantages of Breakdown Maintenance

1. Involves low cost investment for maintenance.
2. Minimal planning is required
3. The process is very simple so it is easy to understand
4. Fewer staff are required as less work is done day-to-day

Disadvantages of Breakdown Maintenance

1. Production is affected – either delayed or stopped
2. Leads to hurried maintenance - this results into poor quality maintenance
3. The plant depreciates very fast
4. Cost of maintenance is high – as down time cost and replacement cost will be high
5. Leads to direct loss of profit
6. Leads to increased accidents
7. More wastage of material
8. Not suitable for equipments like cranes, boilers, lifts, hoists etc.

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 PREVENTIVE MAINTENANCE
 Preventive Maintenance – is also known as preventative maintenance
 Preventive Maintenance - is the prevention of equipment breakdowns before it happens.
 It is performed periodically in order to reduce the incidence of equipment failure and the
costs associated with it.
 Preventive Maintenance - is set on a schedule based on calendar dates or usage, often at the
recommendation of the manufacturer.

 Preventive maintenance includes: -

i. Inspections,
ii. Adjustments,
iii. Regular service
iv. Planned shutdowns
 It is a method of maintenance aimed at avoiding or preventing breakdowns.
 Preventive maintenance is regularly performed on a piece of equipment to reduce the
likelihood of failure.

Preventive Maintenance Cost

 Planned maintenance is much less costly than the reactive maintenance.

Cost of Unplanned Outages

 There are a variety of other costs associated with unplanned outages such as: -
1. Lost production,
2. Overtime,
3. Idle equipment
4. Expedited shipments and
5. Other “hidden” costs which can include:
 Safety issues
 Uncontrollable and unpredictable budget costs
 Shorter life expectancy for equipment
 Greater chance of inspection failure
 Increased downtime for equipment and employees
 Repeat issues and breakdowns

Benefits of Preventive Maintenance

1. Minimizes the possibility of unanticipated break downs
2. Making the plant and machines always available and ready for use.
3. Maintaining the value of the equipment
4. Maintaining optimum productivity
5. Maintaining the accuracy of the machineries
6. Reducing work content during maintenance
7. Ensuring the safety to workmen
8. Extending the life of assets, and increasing equipment up time
9. Increasing productivity and efficiency
10. Reducing maintenance costs

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Procedure for Preventive Maintenance
 This involves
i. Maintaining machine Records
ii. Preparing Inspection checklist
iii. Inspection as per check list
iv. Taking a corrective action

1. Maintaining Machine Records

 To carry out the preventive maintenance effectively all the details about the machines should
be kept in records.
 These details are: -
 Type of equipment and description
 Name of the manufacturer
 Cost and date of the purchase
 Cost and date of planned repairs
 Breakdowns if any and their dates and reasons
 List of spare parts and their code numbers

2. Preparing Inspection Checklist

 The components to be inspected on regular intervals are listed i.e. what are to be inspected
daily/ weekly/ monthly are listed.
3. Inspection as per check list and corrective action
 Inspection and corrective action can be done as follows: -
i. Routine up-keep - adjustment of guide plates, lubrication and cleaning
ii. Periodic inspection – Visual inspection – Overhauls, scheduled replacements etc.

 These maintenance works are done without disturbance to the production activities.
 In preventive maintenance, the cost of maintenance will be high because: -
i. Many people are involved in inspection, record keeping and maintenance work.
ii. More number of spare parts are stocked.
iii. The parts are replaced before the end of their life.

Preventive Maintenance Tools

 These tools include: -
1. Audio sensitive gauges
2. Optical tools
3. Pressure gauges
4. Temperature gauges
5. Vibration analyzers
6. Computerized Maintenance Management System (CMMS)

Advantages of Preventive Maintenance

1. Reduced break downs and down time
2. Lesser overtime to maintenance people
3. Grater safety to workers
4. Low maintenance and repair cost
5. Less stand –by equipment needed.
6. Reduced production cost
7. Increased equipment life
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8. Increase workers morale – as no stoppage of work.
9. Better product Quality
10. Less material wastages.

Disadvantages of Preventive Maintenance

1. Catastrophic failures still likely to occur.
2. Labor intensive.
3. Includes performance of unneeded maintenance.
4. Potential for incidental damage to components in conducting unneeded maintenance.

Planned Maintenance
 Planned Maintenance – is also known as: -
 Planned Preventive Maintenance (PPM)
 Run-To-Failure Maintenance
 Scheduled Maintenance

 Planned Maintenance - is a proactive approach to maintenance in which maintenance work

is scheduled to take place on a regular basis.
 Planned Maintenance - is a scheduled maintenance activity, or service visit.
 It is done to ensure that the equipment, or equipment components, are operating correctly and
within the manufacturer's recommendations.
 It includes preventive maintenance tasks such as checking oil levels, when those tasks
are preplanned.
 The schedule for planned maintenance tasks can be based on: -
i. Equipment running hours
ii. Number of items produced
iii. Distance traveled, or
iv. Other measurable factors.

Note
 Maintenance is done according to the recommendation of the supplier of the equipment.
 This is usually done at predetermined dates.

Objective of Planned Maintenance

 The primary objective of planned maintenance is to maximize equipment performance.
 This is achieved by keeping the equipment: -
 Running safely for as long as possible,
 The equipment free deteriorating or
 Avoiding unplanned outages.

Planned Maintenance Activities

 Planned maintenance activities - includes any maintenance work scheduled in advance.
 For example,
 Changing the oil in a vehicle because the oil light came on is not planned maintenance.
 Changing the oil because the vehicle had gone 3,000 miles would be planned maintenance.
 Maintenance activities are well planned.
 In planned maintenance, the plant is shut down and following are done:-
i. Inspection,

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 ii. Repairing and
iii. Replacing of worn out parts

Maintenance Plan Details

 The following details are planned: -
i. Time of maintenance
ii. Material (Spare parts) requirement.
iii. Men requirement
iv. Maintenance tools and equipment needed.
v. Allocation of work to maintenance people.
vi. Estimated cost

Planned Maintenance Workflow

1. Identify the problem and create a work order

 Planned maintenance begins with outlining the scope of the work to be completed.
 This is done in response to: -
 A work order or
 Based on a repeating schedule.

 The operator or supervisor who detects the issue needs to get the right information to the
maintenance planner.
 This information includes: -
 Details about the problem,
 The asset in question, and
 Any additional problems that may be related to it.
2. Inspect the asset and premises where work will be performed
 The maintenance planner outlines the details of the work to be performed.
 This includes: -
i. The scope of the work
ii. What tools will be required, and
iii. Whether replacement parts or specific materials are needed.

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 The planner also inspects the worksite to ensure worksite is free from disturbances such as; -
temporary equipment, materials, and scaffolding
3. Order the necessary parts and prescribe a process to complete the work
The details of the procedures needed to complete the work successfully is prepared.
Successful completion of a maintenance task requires details such as: -
 Shutdown procedures
 Access requirements, and
 Safety precautions.

4. Add a priority level to the work order

 Once the work is outlined, it needs to be prioritized.
 Any necessary materials should be ordered.
 The maintenance planner should handle those tasks to make sure the work is ready to go once
it’s scheduled.
5. Schedule and complete planned maintenance
 When the planning process is complete, the scheduling phase begins.
 Scheduling maintenance - is a separate process from maintenance planning.
 The two rely heavily on one another to make sure preventive maintenance is completed
successfully.

Benefits of Planned Maintenance

 Planned maintenance offers various benefits to companies on top of reducing unplanned
downtime.
 These benefits include:
1. Reduced maintenance costs
 By outlining a preventative maintenance plan, small problems and easy repairs can be done
before they turn into big failures and costly repairs.
2. Extended asset life/ Increase Equipment Life
 Frequently servicing assets increases their lifecycle. Maintaining equipment and keeping it
operating in good condition will extend the amount of time that it is operational, so it won’t
need to be replaced as often.
3. Increased workplace safety
 Preventing equipment failure ensures that operators and other workers in close proximity to
the equipment are safe with minimized risk of disaster.
4. Improved workplace culture/reduces equipment & employee downtime
 Planned maintenance reduces both equipment downtime and employee downtime.
 Planning out preventative maintenance tasks, and relieving the stress of unexpected
equipment failures will keep employees active, collaborating and overall happier.
5. Planned maintenance decreases downtime
 Faults, failures, and breakdowns interrupt entire production processes, and that could result
in unplanned downtime.
 Downtime is expensive - considering how labour and operations costs continue to mount
while productivity is at a standstill.

Other direct benefits of planned maintenance include: -

1. Reduces unplanned equipment downtime and improves overall equipment performance.
2. Repair costs are reduced because problems are fixed while they are minor.

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 3. More efficient use of manpower and other resources because maintenance work, parts
inventory, tools and financial costs, can be spread more evenly throughout the year.
4. Better planning of spare parts use and ordering.
5. Helping to ensure the manufacturer's requirements for warranty compliance are met.
6. Reducing overall maintenance costs.

There are also a number of secondary benefits that come from using planned maintenance.
These include:
1. Improved workplace safety.
2. Procedures are established to plan the use of, monitor, and control maintenance
resources.
3. Improves the communication between maintenance and operations.
4. Provides a daily plan for maintenance supervisors such that employees have a full day of
work every day.
5. Establishes a performance monitoring system that allows maintenance activities to be
better evaluated and improved.

ROUTINE MAINTENANCE
 Routine Maintenance - are maintenance activities such as regular inspections or machine
servicing.
 Routine maintenance is done on a regular basis, whether that be daily, weekly, monthly, or
yearly.
 Routine maintenance is an important part of keeping systems up to date and functional.
 Routine maintenance involves: -
1. Cleaning equipment
2. Checking system performances

Routine Maintenance Workflow

Overview
 Routine maintenance tasks are small and simple in nature.
 They only require basic maintenance skills to perform well.
 They may be completed daily, weekly, monthly, quarterly, or annually.

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Routine maintenance helps in:-
i. Extending the life of their assets
ii. Reducing emergency maintenance,
iii. Keeping their production lines or facilities up and running more consistently.

 Routine maintenance is a type of preventive maintenance

Examples of Routine Maintenance

 These are: -
 Cleaning shared areas
 Inspecting and cleaning units when residents move in or out, or
 Changing filters or other components in the HVAC system.

Routine maintenance in a factory setting involves: -

 Lubricating
 Cleaning, and adjusting machines,
 Replacing equipment parts on a schedule,
 Inspecting certain components, or
 Performing conditioned monitoring exercises.

Benefits of Routine Maintenance

1. Increased equipment Reliability
2. Health Benefits – clean environments
3. Improved Efficiency
4. Greater Comfort using equipments
5. Reduced Need for Repairs
6. Saves repair costs
7. A Longer System Life

Advantages to Routine Maintenance

1. It helps in keeping the equipment up to date
2. It reduces repair & corrective maintenance costs
3. It makes the equipment to be more reliable
4. It keeps the equipment efficient and economical

Objectives of Maintenance Management

 The more specific objectives of maintenance management are as follows: -
1. To optimize the reliability of equipment and infrastructure;
2. To ensure that equipment and infrastructure are always in good condition;
3. To carry out prompt emergency repair of equipment and infrastructure so as to secure the
best possible availability for production;
4. To enhance, through modifications, extensions, or new low-cost items, the productivity
of existing equipment or production capacity;
5. To ensure the operation of equipment for production and for the distribution of energy
and fluids;
6. To improve operational safety;
7. To train personnel in specific maintenance skills;
8. To advise on the acquisition, installation and operation of machinery;
9. To contribute to finished product quality;
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 10. To ensure environmental protection.

Advantages of Good Maintenance

1. Life of machinery and equipments are increased
2. Production takes place as per the schedule.
3. Products are delivered to customers in time and hence high level of customer satisfaction can
be expected
4. Machines are in good condition. Hence quality of the products will be good.
5. No production loss
6. Machinery is not damaged
7. No idle time of men and machines. Hence their utility increases

Disadvantages of Poor Maintenance

1. Machines may be damaged. This is a loss
2. Poorly maintained machines will produce poor quality products
3. More wastage of materials.
4. Break down of machines makes both men and machine in idle position. So production time is
wasted. This will increase cost of production
5. Poor maintenance cause accidents.
6. Due to poor maintenance, life of machine is reduced.
7. If a part of equipment goes out of order in a flow production factory, then the entire
production line will soon come to halt. This leads to heavy loss in productivity as well as
monetary loss.

Comparison of preventive maintenance & corrective maintenance

Preventive Maintenance Corrective Maintenance
1. It is carried out on a working equipment in It is carried out once the equipment fails
order to avoid failure
2. Its objective is to increase the reliability of Its objective is to restore the failed
the equipment system back to satisfactory operation
within shortest time.
3. It is a planned method of routine It is performed unpredictably because
maintenance there is no prior intimation of oncoming
failure
4. There is no down-time since maintenance is Equipment failure results in down time of
done during off-time the equipment
5. It involves replacement of worn-out or Involves repairing replacement of faulty
degraded components/parts components which have caused failure
6. It is a preventive action on working system It is a curative action to bring the faulty
to avoid failure system back to working condition.

Maintenance Costs:
 Breakdown of equipment makes the workers and the machines idle.
 This results in: -
i. Loss of production
ii. Delay in schedules and
iii. Expensive emergency repairs.

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 These downtime costs usually exceed the preventive maintenance costs of inspection, service
and scheduled repairs up to the point M shown in figure below

 Beyond this optimal point –

 An increasingly higher level of preventive maintenance is not economically justified.
 It is economical to adopt breakdown maintenance policy.
 The optimal level of maintenance activity M, is easily identified on a theoretical basis.

Costs associated with maintenance are: -

1. Down time (Idle time cost) cost due to equipment breakdown.
2. Cost of spares or other material used for repairs.
3. Cost of maintenance labour and overheads of maintenance departments.
4. Losses due to inefficient operations of machines.
5. Capital requirements required for replacement of machines.

Maintenance Policy & Repair

 Maintenance Policy – defines the approaches towards maintenance of the plant.

Factors to consider before choosing the maintenance policy

 There are:
i. Risks of failure
ii. Maintenance costs
iii. Asset performance
iv. Asset reliability

Types of Maintenance Policies

 There are three different maintenance policies to choose from:
1. Use-based maintenance
2. Failure-based maintenance
3. Condition-based maintenance

1. Use-Based Maintenance - is maintenance that is triggered by time, or event e.g. changing

the oil in your car every 3,000 miles.
2. Failure-based maintenance - refers to running an asset to failure. Maintenance is done after
plant failure.
3. Condition-based maintenance - is a maintenance policy that assesses the actual condition of
an asset to determine whether maintenance needs to be done.

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Significance of the Maintenance Policy
 Maintenance policy ensures that: -
1. Equipments are always in ready and reliable condition.
2. Equipments are always calibrated.
3. There are no major breakdowns.
4. Costs are always controlled.

Lack of an effective maintenance policy results in: -

1. Full capacity utilization may not be achieved.
2. Increase in production cost as fixed labor cost cannot be reduced.
3. Increase in maintenance cost as more spare parts are required.
4. Reduction in product quality and increase in wastage.
5. Safety of workers and operators in jeopardy.

Maintenance Department
 Maintenance department is responsible with planning and scheduling of maintenance.
 Planning and scheduling needs to ensure that production is not disturbed.

Duties of Maintenance Department

1. Identifying the equipment for maintenance and technique for maintenance.
2. Categorizing maintenance into routine, priority and emergency.
3. Planning maintenance considering cost, time, space etc.
4. Planning for material requirements for maintenance.
5. Budgeting time and money requirements.

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