Preventive Maintenance

Introduction
It is necessary to keep materials, tools and equipment in good condition in
order to achieve desired result. If the working equipments are in good
running condition, the products obtained will be of required quality
and the process will be reliable. Therefore it is necessary to maintain
the plant.
Maintenance is a set of organized activities that are carried out in order to
keep the item in its best operational condition with minimum cost
required.
Maintenance Engineering is the discipline and profession of applying
engineering concepts to the optimization of equipment, procedures, and
departmental budgets to achieve better maintainability, reliability, and
availability of equipment.
Maintenance, and hence maintenance engineering, is increasing in
importance due to rising amounts of equipment, systems, machineries and
infrastructure. Since the Industrial Revolution, devices, equipment,
machinery and structures have grown increasingly complex, requiring a host
of personnel, vocations and related systems needed to maintain them.
Maintenance Definition
British standard Glossary of Terms defined maintenance as:
The combination of all technical and administrative actions, including
supervision actions, intended to retain an item in, or restore it to, a state in
which it can perform a required function.
Maintenance Activities
Activities of maintenance function could be either repair or replacement
activities, which are necessary for an item to reach its acceptable
productivity condition or these activities, should be carried out with a
minimum possible cost.

Maintenance Cost
Because of breakdowns, both the machinery as well as the manpower
is left idle, per force.
These results in production, delay in schedules and emergency repairs.
The downtime costs generally exceed the preventive maintenance costs
of inspection, service and scheduled repairs.
Costs associated with maintenance are:
1. Downtime cost due to equipment breakdown.
2. Cost of spares and other material used for repairs.
3. Cost of maintenance labor and overheads of maintenance department.
4. Losses due to inefficient operations of machines.
5. Capital requirement for replacement of machines.
Maintenance History
In the pre-world War II, people thought of maintenance as an added cost to
the plant which did not increase the value of finished product. Therefore, the
maintenance at that era was restricted to fixing the unit when it breaks
because it was the cheapest alternative.
During and after World War II at that time when the advances of
engineering and scientific technology developed, people developed other
types of maintenance, which were much cheaper such as preventive
maintenance. In addition, people in this era classified maintenance as a
function of the production system.
Nowadays, increased awareness of such issues as environment safety,
quality of products and services makes maintenance one of the most
important functions that contribute to the success of the industry. Worldclass companies are in continuous need of a very well organized
maintenance program to compete world-wide.

Maintenance Objectives
Maintenance objectives should be consistent with and subordinate to
production goals. The relation between maintenance objectives and
production goals is reflected in the action of keeping production machines
and facilities in the best possible condition. These are:
Maximizing production or increasing facilities availability at the
lowest cost and at the highest quality and safety standards.
Reducing breakdowns and emergency shutdowns.
Optimizing resources utilization.
Reducing downtime.
Improving spares stock control.
Improving equipment efficiency and reducing scrap rate.
Minimizing energy usage.
Optimizing the useful life of equipment.
Providing reliable cost and budgetary control.
Identifying and implementing cost reductions.
Types of Maintenance
Run to Failure maintenance (RTF)
Preventive Maintenance (PM)
Corrective Maintenance (CM)
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,

labor and equipment.
Disadvantages:
- Its activities are expensive in terms of both direct and indirect
cost.
- 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.
- Its activities are very difficult to plan and schedule in advance.
This type of maintenance is useful in the following situations:
- The failure of a component in a system is unpredictable.
- The cost of performing run to failure maintenance activities is
lower than performing other activities of other types of
maintenance.
- The equipment failure priority is too low in order to include the
activities of preventing it within the planned maintenance
budget.

Preventive Maintenance(PM)
Preventive maintenance, where equipment is maintained before break
down occurs. This type of maintenance has many different variations
and is subject of various researches to determine best and most
efficient way to maintain equipment. Recent studies have shown that
Preventive maintenance is effective in preventing age related
failures of the equipment. For random failure patterns which amount
to 80% of the failure patterns, condition monitoring proves to be
effective.
British Standard 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 advantages of applying preventive maintenance activities are to
satisfy most of maintenance objectives.
The factors that affect the efficiency of this type of maintenance:
- The need for an adequate number of staff in the maintenance
department in order to perform this type of maintenance.
- The right choice of production equipment and machinery that is
suitable for the working environment and that can tolerate the
workload of this environment.

- The required staff qualifications and skills, which can be gained

through training.
- The support and commitment from executive management to
the PM program.
- The proper planning and scheduling of PM program.
- The ability to properly apply the PM program.
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 minimized.
Its activities include replacements, adjustments, major overhauls,
inspections and lubrications.
The effectiveness of a preventive maintenance schedule depends on the
RCM (Reliability Centered Analysis) analysis which it was based on, and
the ground rules used for cost-affectivity.
Reliability Centered Maintenance (RCM) is a process to ensure that assets
continue to do what their users require in their present operating context.
It is generally used to achieve improvements in fields such as the
establishment of safe minimum levels of maintenance, changes to operating
procedures and strategies and the establishment of capital maintenance
regimes and plans. Successful implementation of RCM will lead to increase
in cost effectiveness, machine uptime, and a greater understanding of the
level of risk that the organization is managing.
Reliability centered maintenance is an engineering framework that enables
the definition of a complete maintenance regime. It regards maintenance as
the means to maintain the functions a user may require of machinery in a
defined operating context. As a discipline it enables machinery stakeholders
to monitor, assess, predict and generally understand the working of their
physical assets.
RCM can be used to create a cost-effective maintenance strategy to address
dominant causes of equipment failure. It is a systematic approach to defining
a routine maintenance program composed of cost-effective tasks that
preserve important functions.

The important functions of a piece of equipment to preserve with routine

maintenance are identified, their dominant failure modes and causes
determined and the consequences of failure ascertained. Levels of criticality
are assigned to the consequences of failure. Some functions are not critical
and are left to "run to failure" while other functions must be preserved at all
cost. Maintenance tasks are selected that address the dominant failure
causes. This process directly addresses maintenance preventable failures.
RCM emphasizes the use of Predictive Maintenance (PdM) techniques in
addition to traditional preventive measures.
Reliability centered maintenance is an engineering framework that enables
the definition of a complete maintenance regime. It regards maintenance as
the means to maintain the functions a user may require of machinery in a
defined operating context. As a discipline it enables machinery stakeholders
to monitor, assess, predict and generally understand the working of their
physical assets. RCM is kept live throughout the "in-service" life of
machinery, where the effectiveness of the maintenance is kept under
constant review and adjusted in light of the experience gained.
Preventive maintenance (PM) has the following meanings:
1. The care and servicing by personnel for the purpose of maintaining
equipment and facilities in satisfactory operating condition by
providing for systematic inspection, detection, and correction of
incipient failures either before they occur or before they develop into
major defects.
2. Maintenance, including tests, measurements, adjustments, and parts
replacement, performed specifically to prevent faults from occurring.
The primary goal of maintenance is to avoid or mitigate the consequences of
failure of equipment. This may be by preventing the failure before it actually
occur which Planned Maintenance and Condition Based Maintenance help
to achieve. It is designed to preserve and restore equipment reliability by
replacing worn components before they actually fail. Preventive
maintenance activities include partial or complete overhauls at specified
periods, oil changes, lubrication and so on. In addition, workers can record
equipment deterioration so they know to replace or repair worn parts before
they cause system failure. The ideal preventive maintenance program would
prevent all equipment failure before it occurs.

Preventive maintenance can be described as maintenance of equipment or

systems before fault occurs. It can be divided into two subgroups:

Planned maintenance and

Condition-based maintenance.

The main difference of subgroups is determination of maintenance time, or

determination of moment when maintenance should be performed.
While preventive maintenance is generally considered to be worthwhile,
there are risks such as equipment failure or human error involved when
performing preventive maintenance, just as in any maintenance operation.
Preventive maintenance as scheduled overhaul or scheduled replacement
provides two of the three proactive failure management policies available to
the maintenance engineer. Common methods of determining what
Preventive (or other) failure management policies should be applied are;
OEM recommendations, requirements of codes and legislation within a
jurisdiction, what an "expert" thinks ought to be done, or the maintenance
that's already done to similar equipment, and most important measured
values and performance indications.
In a nutshell:

Preventive maintenance is conducted to keep equipment working

and/or extend the life of the equipment.
Corrective maintenance, sometimes called "repair," is conducted to
get equipment working again.

Corrective Maintenance (CM)

Corrective maintenance, where equipment is maintained after break down.
This maintenance is often most expensive because worn equipment can
damage other parts and cause multiple damages.
Corrective maintenance is probably the most commonly used approach, but
it is easy to see its limitations. When equipment fails, it often leads to
downtime in production. In most cases, this is costly business. Also, if the
equipment needs to be replaced, the cost of replacing it alone can be
substantial. It is also important to consider health, safety and environment
(HSE) issues related to malfunctioning equipment.

Corrective maintenance can be defined as the maintenance which is required

when an item has failed or worn out, to bring it back to working order.
Corrective maintenance is carried out on all items where the consequences
of failure or wearing out are not significant and the cost of this maintenance
is much greater than preventive maintenance.
Corrective maintenance is the program focused on the regular task that will
maintain all the critical machinery and the system in optimum operating
conditions. The major objectives of the program are to:
1. Eliminating breakdown,
2. Eliminating deviation,
3. Eliminating unnecessary repairs,
4. Optimize all the critical planned system.

Predictive Maintenance (PM)

Condition Monitoring
Introduction
Condition Monitoring (CM) is the process of monitoring a parameter of
condition in machinery (vibration, temperature etc.), in order to identify a
significant change which is indicative of a developing fault. It is a major
component of Predictive Maintenance (PdM). The use of conditional
monitoring allows maintenance to be scheduled, or other actions to be taken
to prevent failure and avoid its consequences. Condition monitoring has a
unique benefit in that conditions that would shorten normal lifespan can be
addressed before they develop into a major failure. Condition monitoring
techniques are normally used on rotating equipment and other machinery
(pumps, electric motors, internal combustion engines, and presses), while
periodic inspection using non-destructive testing techniques and fit for
service (FFS) evaluation are used for stationary plant equipment such as
steam boilers, piping and heat exchangers.

Condition Monitoring within a Reliability Context: Where condition

monitoring is used as a proactive defect elimination strategy to drive failure
prevention the benefits really add up with improved reliability giving
extended Mean Time between Failures and additional Plant Availability.
There have been recorded instances where the gains in improved plant
uptime have lead to deferment of expensive plant expansion.
Definition of Condition Monitoring: The process of systematic data
collection and evaluation to identify changes in performance or condition
of a system, or its components, such that remedial action may be planned in
a cost effective manner to maintain reliability. While the basic definition of
Condition Monitoring (CM) may have general application across many
industries, the objectives for Condition Based Maintenance (CBM) may
vary greatly.

CM uses selected measurements to detect changes in operating

conditions: Many failure modes have measurable responses and
develop over periods of time. These are the ideal applications for
CBM. Sampling may be continuous, (e.g. turbo-machinery) or
periodic (e.g. monthly survey on conveyor drive).

CM gives early warning of potential failure:

If the measured parameters are well chosen and properly measured
and analyzed, there will be valuable information gained for
maintenance planning purposes. It is essential that what defines
normal is understood and documented so that the severity of
variations can be measured.

CM gives information about the nature of the failure:

From this a prognosis should be able to be determined. The rate of
sampling and access to maintenance history on the machine may
have an influence on the quality of the final decisions made.

CM allows management of failure to full life potential:

Identification of a failure mode does not necessarily mean that an
immediate maintenance action is needed. Just when maintenance
action must be taken is the toughest part of managing a CBM
program. Your reputation may depend on it. The best course is to
involve as many informed people in the decision making process.

CM evaluates corrective action: Immediately after a machine has

been repaired it should be subject to condition monitoring testing.
This will potentially identify assembly or installation faults that
may lead to early failure (infant mortality) or affirm the quality of
improvement achieved through the application of improved work
practices or maintenance standards.

Trends for Condition Monitoring in the 21st Century:

The development of smart sensors, and other low-cost on-line
monitoring systems that will permit the cost-effective continuous
monitoring of key equipment items.

The increasing provision of built-in vibration sensors as standard

features in large motors, pumps, turbines and other large equipment
items
Increasingly sophisticated condition monitoring software, with rapidly
developing "expert" diagnosis capabilities
The acceptance of Condition Monitoring within the "mainstream" of
Operations and Maintenance, with Production operators increasingly
utilising Condition Monitoring technologies as part of their day-to-day
duties

Increasing integration, and acceptance of common standards for

interfacing Condition Monitoring software with CMMS and Process
Control software
An increasing focus on the business implications and applications of
Condition Monitoring technologies, leading to the utilisation of
Condition Monitoring technologies to improve equipment reliability
and performance, rather than to merely predict component failure.
A reduction in the cost-per-point of applying Condition Monitoring
technologies - possibly leading to more widespread use of these
technologies.

How to view PM (Preventive maintenance) and PdM (Predictive

maintenance)
Effective PM or PdM is like a skyscraper with four sides. PM initiative
commonly fails to meet expectations or just gradually fade out of existence
when one side is neglected. If the program is to be successful it needs to
have structural integrity in all four areas:
1. Engineering: Analysis of statistics of failure, uptime, and repair is
included in the engineering pillar of PM.
2. Economic: The task must be worth doing. This economic question
is critical.
3. People- Psychological: The people doing the PM have to be
motivated to the extent that they actually do the designated tasks
properly.
4. Management: PM has to be built into the systems and procedures
that control the business and these systems must be designated so that
good PM results.
What is the Mission of Maintenance?
The Mission definitions ranged from quick reaction times in fixing
breakdowns to serving the customer more efficiently. Some firma are intent
on reducing downtimes and other focus on cost control or quality. A few
focus on safety or environmental security. All these missions are good,
useful, and important.
In todays organizations the creed is that everyone must add value to the
product. Every one and everything is expendable, outsource able. There is a

conflict between the old mission statements and the new culture. The new
mission is: The mission of the maintenance department is to provide
reliable physical assets and excellent support for its customers by reducing
and eventually eliminating the need for maintenance services.
New role:
The new mission requires a re-thinking of traditional roes. On one side
maintenance must merge with machine, building and tool design to
integrate maintainability improvements into designs on an ongoing basis.
The accumulated knowledge and lessons of maintenance will be merged
immediately into the design professions. There will be a revolving door
between the people who design and the people who maintain. On the
other side, routine maintenance activity will be merged increasingly into
operations.