f Maintenance systems

Types of Maintenance - Glossary

• Autonomous Maintenance - that is performed by the machine operator rather than the
maintenance staff.
– Autonomous maintenance includes tasks such as lubricating and tightening machine
parts.
• Breakdown Maintenance - Maintenance performed on broken machines to restore
them to working order.
• Periodic Maintenance - Maintenance performed on a calendar basis.
• Planned Maintenance - Maintenance that is performed purposely and regularly in
order to prevent a machine from deteriorating or breaking down.
• Predictive Maintenance - Maintenance performed based on the known and expected
behavior, condition, and history of the machine.
• Preventive Maintenance - Maintenance performed while a machine is still in working
order to keep it from breaking down.
– Preventive maintenance includes lubricating, tightening, and replacing worn parts.
• Corrective Maintenance - Corrective maintenance is a form of system maintenance
which is performed after a fault or problem emerges in a system, with the goal of
restoring operability to the system.
– In some cases, it can be impossible to predict or prevent a failure, making corrective
maintenance the only option.

Planned Maintenance
Objectives:
• Increase Equipment Reliability and Production Up -Time
• Minimize the maintenance cost by
1) reducing breakdowns
2) development of efficient maintenance methods
To clarify which parts and locations of which equipment should receive what type of
maintenance and to implement it in a planned manner
• Under this type of maintenance, the work is planned before hand to avoid random
failures.
• It decides not only the when and what of maintenance work, but also by whom it would
be undertaken.
• To meet the requirements of the planned maintenance, first of all work-study has to be
carried out to decide the periodicity of maintenance work.
• Time-study can also suggest ways and means of devising optimal maintenance
schedules for the given system

Planned Maintenance – Steps

Step 1: Evaluate Equipment and Understand Current Conditions
Step 2: Restore Deterioration and Correct Weaknesses
Step 3: Build an Information Management System
Step 4: Build a Periodic Maintenance System
Maintenance performed on a calendar basis.
Step 5: Build a Predictive Maintenance System
Maintenance performed based on the known and expected behavior, condition, and
history of the machine.
Step 6: Evaluate the Planned Maintenance System

Maintainability Vs Reliability

• Maintainability is defined as the probability of restoration of a failed device or

equipment or asset to operational effectiveness within a specified period of time through
the prescribed maintenance operations.
– It is associated with the design of the assets to be maintained.
– It is a measure of the ease of maintenance.
– The parameter for expressing the maintainability is Mean Time to Repair (MTTR).
– The total corrective maintenance time / the total number of corrective maintenance
actions during a given period of time.
• Reliability is the probability that an asset or a system will operate satisfactorily for
some determined period of time, under the working conditions for which it was
designed.
– The parameters expressing reliability are Failure Rate (FR) or Mean Time Between
Failures (MTBF)
– (NUMBER OF PIECES OF EQUIPMENT X TIME PERIOD) / NUMBER OF
FAILURES DURING THAT TIME
– Eg. (1000 machines * 12 months) / 100 failures = 120 months MTBF

Autonomous Maintenance?
• Maintenance that is performed by the machine operator rather than the maintenance
staff.
• Autonomous maintenance includes tasks such as lubricating and tightening machine
parts.
• SHARED RESPONSIBILITY OF MAINTAINING ”BASIC CONDITIONS” OF
EQUIPMENT BETWEEN PRODUCTION AND MAINTENANCE
• Daily/Time-Based Maintenance
– Cleaning
– Lubrication
– Tightening
• Daily inspection by using 5 SENSES
• Right operation, right adjustment, right setting

Planned Maintenance – Main Activities

Preventive Maintenance
• Objectives: To detect any condition that may cause machine failure before such
breakdown occurs.
– This makes it possible to plan and schedule the maintenance work without interruption
in production schedule and thus improves the availability of equipment.
• Preventive maintenance is the utilization of planned and coordinated inspections,
adjustments, repairs and replacements in maintaining an equipment or plant.
• Under this type of maintenance, a systematic and extensive inspection of each item of
equipment (or the critical parts) is made at predetermined intervals.

Preventive Maintenance - Activities

• Routine attention :
– This involves maintenance activities that take regular care of the machines or assets.
– These activities are designed to preserve the assets of the organization at a given
standard of maintenance which conforms to its financial and operating policies.
– Routine servicing includes cleaning, oiling, and adjusting.
• Routine examination:
– Routine examinations are carried out to identify hidden (inactive) faults or items prone
to failure.
– This type of preventive maintenance work helps to detect faults before they can
actually occur.
• Preventive replacement :
– The preventive maintenance work comprises preventive replacement of parts and
components that have a definite life.
– Such type of replacements help to avoid emergency situations and prolonged
downtime and risk of hazards associated with sudden breakdowns.
• Inspection measurements:
– Inspection measurements comprise jobs of preventive maintenance that aim at
identifying the degradation rate and such items which are at unacceptable service
conditions.
– This type of maintenance work requires many costly instruments and laboratory
testing facilities.

Corrective Maintenance
• The use of planned preventive maintenance brings out the nature of repetitive failures
of a certain part of the equipment.
• When such repetitive type of failures are observed, corrective maintenance can be
applied so that reoccurrence of such failures can be avoided.
• These types of failures can be reported to the manufacturer to suggest modifications
to the equipment.
• Corrective maintenance can be defined as the maintenance carried out to restore an
equipment that has stopped working to acceptable standards.
• For example, an engine may be in working condition, but does not take its full load
because of worn-out piston rings.
– Thus if the piston rings are replaced, it will bring back the performance of the engine
to the specified level.
– The corrective maintenance, if properly carried out, will eventually bring down the
maintenance costs and there will also be a reduction in downtime-of the equipment.

Breakdown Maintenance
• The basic concept of this type of maintenance is not to do anything as long as
everything is going on well.
• Hence no work is done until a component or equipment fails or becomes inoperative.
• In other words, the work is called upon to be done in the case of an emergency failure
when necessary repairs are carried out to bring back the equipment to its original
working condition.
• From the time machines came into existence, this type of maintenance is still in
practice and being followed in many organizations.
• The equipment is allowed to run till it stops working and no efforts are made in
advance to prevent the failure of parts.
• Therefore breakdown maintenance occurs suddenly and all the repair and
maintenance work pertaining to it is only done when the equipment stops working.
• If this system is alone followed, it will lead to poor operational availability of the
equipment as spare parts may not be readily available.

Breakdown Maintenance- Limitations

• Even though it may appear to be an economical proposition, work would greatly
suffer if the machine is not restored to operational condition immediately.
• In this type of maintenance, during the repair time, no proper care is taken to know the
real cause of the breakdown, which in turn may lead to frequent failures of the same
kind.
• With high-cost production systems being put in use, the limitations of the breakdown
maintenance were realized. and consequently other types of maintenance work were
introduced .
• The most important of all was the planned preventive maintenance at that time.
• Now even much better maintenance functions such as condition monitoring are also
available.

• Work that must be done to keep building systems, campus areas, and equipment
operating in an efficient manner.

• Examples are:
– Replacement of burned out lights and ballasts.
– Repair of broken stair treads and windows, inoperative door locks, light switches and
outlets, parking gates and parking meters, plumbing leaks, equipment such as
compressors, pumps, office and classroom furniture.
– Maintenance of roads, grounds, walks, and signs.
– Belt tightening, water treatment, control adjustment, lubrication, and filter changing.

Running maintenance tasks

 Task Method
Cleaning The machine or Slides cleaned
equipment should with a rag to
be kept clean at all remove excess
times. dust and oil.
Tooling Tools need to be Replace tool when
sharp at all times. it is blunt, burnt or
damaged.
Lubricating Moving parts need Topping up oil
to be lubricated on levels. Refer to
a regular basis. your machine
manual for further
instructions on
type of oil and
where to fill.
Air filter The air filter may Refer to your
need to be drained machine manual
or replaced. for instructions on
how to drain the
filter.

Shutdown Maintenance

• Shut down can be defined as “scheduled down period for a plant for scheduled
maintenance for an extended period of time”.
• Shutdowns provide unique opportunities to a maintenance department not normally
available during standard operation or even during short shutdown periods.
• A large work is required to schedule into a relatively short period of time.
• The process of project management is generally applied to a maintenance shutdown
in large plants like coal and thermal power stations.
• The critical path method (CPM) or sometimes a Gantt charts is used for planning
shut down.
• Shutdown Maintenance - That can only be performed when the equipment, machine,
or plant has been put out of service.

Condition-based Maintenance
• In an internal combustion engine, the temperature of the cylinders can be monitored
during the operation of the engine to avoid their seizure, but the important bearings can
only be inspected after the engine has been shut down.
• A maintenance technique closely related to PdM that involves monitoring machine
condition and predicting machine failure.
– Many CBM systems are controlled by computers.
Condition-based Maintenance - Types
• Monitoring which can be carried out during the operation of the machine
• Monitoring which can only be carried out after shutdown of the machine.

Condition-based Maintenance
• This kind of maintenance is carried out in response to a significant deterioration in
a unit or system as indicated by a change in a monitored parameter of the equipment or
system based on its condition or performance.
• A condition-based maintenance policy is most suited for high capital cost equipment
and complex replaceable items and also for permanent parts that deteriorate over time
or due to prolong use.
• For this purpose, a good, knowledge of failure data is necessary for effective
implementation of condition-based maintenance.
• This process involves detection diagnosis and proper execution of maintenance
planning.
• On indication of deterioration, the unit can be shut down at a convenient time to
avoid accidental breakdowns.
• The following are the advantages of using the condition-based maintenance:
– Safety. Less number of injuries and fatal accidents to personnel caused by random
failures of machinery.
– Availability. With increased machine availability, there will be an increase in output
and also improvement in the quality of products.

Condition-based Maintenance
• In practice, a trade-off between the breakdown and planned maintenance costs has to
be struck and the parameters influencing the policy should be carefully identified.
• Figure shows the effects of different types of costs involved in performance of the
maintenance function.
Reliability-centered Maintenance

A maintenance approach that prioritizes some machines over others to increase

reliability and optimize financial resources.
• It is used to identify the maintenance requirements of equipment.
• The RCM establishes the functional requirements and the desired performance
standards of equipment and these are then related to design and inherent reliability
parameters of the machine.
• For each function, the associated functional failure is defined, and the failure modes
and effects of the functional failures are analysed.
• The consequences of each failure are established, which fall in one of the four
categories:
• hidden,
• safety or environmental,
• operational, and
• non-operational.
It is the optimum mix of reactive, time- or interval-based, condition based, and proactive
maintenance practices.

Reliability-centered Maintenance
• Reliability Centered Maintenance (RCM) analysis provides a structured framework for
analyzing the functions and potential failures for a physical asset (such as a
manufacturing production line, etc.) with a focus on preserving system functions, rather
than preserving equipment.
• Reliability-centered maintenance is much more than just another way to do
maintenance.
– In a nutshell, it's a way of looking at system performance in terms of the impact of a
failure and then mitigating those results by design, detection, or effective maintenance.
• You don't need to understand every detail about your systems to practice reliability-
centered maintenance; rather, you must understand what components and equipment
can be allowed to fail, what must be monitored, and what the consequences are of the
failure.
• While this approach requires a good understanding of design constraints and system
performance data, you don't need a time-consuming and expensive process to
positively impact most facilities systems.
• Many professionals view reliability-centered maintenance and predictive technologies
as add-on technologies to a preventive maintenance program; however, reliability-
centered maintenance is a tool that redesigns your overall maintenance strategy to
improve system performance.
– An outcome of a reliability-centered maintenance analysis might show that you need
to improve or replace some system components or equipment, improve your monitoring
capabilities, or change or eliminate preventive maintenance activities.

RCM – the 7 questions

• The RCM process entails asking seven questions about the asset or system under
review, as follows:
– what are the functions and associated performance standards of the asset in its
present operating context?
– in what ways does it fail to fulfill its functions?
– what causes each functional failure?
– what happens when each failure occurs?
– in what way does each failure matter?
– what can be done to predict or prevent each failure?
– what should be done if a suitable proactive task cannot be found?

• Reactive Maintenance - performed only after a machine fails or

experiences problems.
• Root Cause Failure Analysis
– It is a process where what appears to be the obvious cause for an accident or
shutdown of equipment is utilized to find out what really caused it.
– A very simple example would be that a pump stopped and water was no longer being
supplied.
– It appears that the pump is the problem.
– But using RCFA and the process, you may find that instead of the pump needing to be
replaced for hundreds of thousands, it was a pressure sensor which was faulty which
signaled to the pump to shut down.
– The sensor may only cost hundreds and by replacing it with the right sensor, the
problem doesn't happen again.

RCFA – an example
• In medicine, it's easy to understand the difference between treating symptoms and
curing a medical condition.
– Sure, when you're in pain because you've broken your wrist, you WANT to have your
symptoms treated – now!
– However, taking painkillers won't heal your wrist, and true healing is needed before the
symptoms can disappear for good.
• But when you have a problem at work, how do you approach it? Do you jump in and
start treating the symptoms? Or do you stop to consider whether there's actually a
deeper problem that needs your attention?
• If you only fix the symptoms – what you see on the surface – the problem will almost
certainly happen again... which will lead you to fix it, again, and again, and again.
• If, instead, you look deeper to figure out why the problem is occurring, you can fix the
underlying systems and processes that cause the problem.
• Root Cause Analysis (RCA) is a popular and often-used technique that helps people
answer the question of why the problem occurred in the first place.
• Root Cause Analysis seeks to identify the origin of a problem. It uses a specific set of
steps, with associated tools, to find the primary cause of the problem, so that you can:
– Determine what happened.
– Determine why it happened.
– Figure out what to do to reduce the likelihood that it will happen again.
• RCA assumes that systems and events are interrelated. An action in one area triggers
an action in another, and another, and so on. By tracing back these actions, you can
discover where the problem started and how it grew into the symptom you're now
facing.

Failure Modes and Effects Analysis

• It is a methodology for analyzing potential reliability problems early in the development
cycle where it is easier to take actions to overcome these issues, thereby enhancing
reliability through design.
• FMEA is used to identify potential failure modes, determine their effect on the
operation of the product, and identify actions to mitigate the failures.
• A crucial step is anticipating what might go wrong with a product.
• While anticipating every failure mode is not possible, the development team should
formulate as extensive a list of potential failure modes as possible.
• In general, it requires the identification of the following basic information:
– Item(s)
– Function(s)
– Failure(s)
– Effect(s) of Failure
– Cause(s) of Failure
– Current Control(s)
– Recommended Action(s)
– Plus other relevant details

Condition Monitoring

The industries all over the world today demand high-technology maintenance
management in view of the high power and speed of machines utilised in the complex
processes/terrain conditions.
• Minimum downtime of machines and reduction in penalty costs are the pressing needs
of every enterprise.
• These considerations are particularly true in the areas of advanced technology such
as aircraft industries, oil well drilling, coal extraction, power plants, and chemical
industries, etc.
• Condition monitoring has to achieve the maintenance objectives in such highly capital
intensive industries.
•Condition monitoring is the process that assesses the health of an equipment/system
at regular intervals or continuously and exposes early faults, if any.
• Basically, it consists of extraction of information about particular parameters from
machines and analysis of data to predict the health of machines without affecting their
operation.
• Condition monitoring leads to undertaking corrective measures only when they are
needed rather than at the scheduled or routine intervals.
• Thus it can eliminate downtime for unnecessary inspections.

•Routine condition monitoring may be carried out by using diagnostic instruments on a

routine or continuous basis.
• The performance and the condition of machinery are monitored to compare against
acceptance standards.
• The acceptance standards are established during the commissioning tests.
• In such tests, parameters are measured against known loads or predetermined
conditions.
• The statistical analysis of the detailed information breakdown has revealed that one-
third of the total available time is lost due to breakdowns.

• Condition monitoring is considered as the most reliable, cost effective and efficient
technique for maintaining the majority of critical equipment such as engines, turbines,
compressors, etc. used in most of the industries today.
• Approximately 20-30 per cent of possible production time goes towards maintenance
of equipment and this can be minimised through effective maintenance.
• Towards this aim, condition monitoring plays a very important role.
• Thus it is necessory to develop an appropriate monitoring system in the overall
maintenance schemes for all machinery.

Condition Monitoring - Advantages

The advantages to be expected from a conditionmonitoring
programme include:
– Cost reduction in preventive maintenance
– Reduction in the number of equipment failures
– Avoidance of consequential damages
– Confidence of the operating personnel and safety
– Condition monitoring also contributes to maintenance planning, maintenance cost
reduction, health and safety programmes and helps in energy conservation too, by
providing early warning of waste and inefficiency arising from faulty operation.

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