CH 5 Is Fullnotes

07-10-2020
Types of Maintenance
Prepared By:
Aakash R. Suthar
What is Maintenance?
&
Why Maintenance?
1
07-10-2020
Maintenance
Maintenance is work that is carried out to
preserve an asset (such as a roof or a heating
boiler), in order to enable its continued use and
function, above a minimum acceptable level of
performance, over its design service life,
without unforeseen renewal or major repair
activities
Reasons for Maintenance

Maintenance serves to protect the owners’ real estate investment in
number of ways
• Physical Integrity
To keep the assets in good working order so as to minimize
disruptions and downtimes.
• Risk Management
To keep the assets in a state of good repair for the owners’ health and
safety.
• Aesthetic Preservation
To keep the assets from deteriorating in appearance and becoming
unsightly.
• Responsible Stewardship
To ensure that the assets achieve their full potential service life.
2
07-10-2020
• Duty of Care
To satisfy a legislated duty that is owed to owners, occupants and
guest on the property.
• Duty to Mitigate
To prevent unnecessary damage to assets that may result in their
premature failure.
Types Of Maintenance
• Breakdown maintenance
• Preventive maintenance
1. Periodic maintenance ( Time based
maintenance - TBM)
2. Predictive maintenance
I. Condition Monitoring
• Corrective maintenance
3
07-10-2020
• Break Down Maintenance
It means that people waits until equipment fails and repair it. Such a
thing could be used when the equipment failure does not significantly
affect the operation or production or generate any
significant loss other than repair cost.
It is a daily maintenance ( cleaning, inspection, oiling and re-tightening

), design to retain the healthy condition of equipment and prevent
failure through the prevention of deterioration, periodic inspection or
equipment condition diagnosis, to measure deterioration. It is further
divided into periodic maintenance and predictive maintenance. Just like
human life is extended by preventive medicine, the equipment service
life can be prolonged by doing preventive maintenance.
• Periodic maintenance
Time based maintenance consists of periodically inspecting,

servicing and cleaning equipment and replacing parts to prevent
sudden failure and process problems
• Predictive maintenance
This is a method in which the service life of important part is

predicted based on inspection or diagnosis, in order to use the
parts to the limit of their service life. Compared to periodic
maintenance, predictive maintenance is condition based
maintenance. It manages trend values, by measuring and
analysing data about deterioration.
4
07-10-2020
• Condition Monitoring
Condition monitoring is the process of determining the condition of
machinery while in operation.
• The key to a successful condition monitoring programme includes:

1. Knowing what to listen for
2. How to interpret it
3. When to put this knowledge to use
• Successfully using this programme enables the repair of problem

components prior to failure.
• Condition monitoring not only helps plant personnel reduce the

possibility of catastrophic failure, but also allows them to order parts
in advance, schedule manpower, and plan other repairs during the
downtime.
It improves equipment and its components so that preventive
maintenance can be carried out reliably. Equipment with design
weakness must be redesigned to improve reliability or
improving maintainability
5
07-10-2020
What is Maintenance?
&
Why Maintenance?
PG Department
Mr. Aakash Rajeshkumar Suthar
Maintenance
PG Department
6
07-10-2020
Maintenance
PG Department
Maintenance
Maintenance is work that is carried
out to preserve an asset (such as a
roof or a heating boiler), in order to
enable its continued use and
function, above a minimum
acceptable level of performance,
over its design service life, without
unforeseen renewal or major repair
activities
PG Department
7
07-10-2020

Physical Integrity
To keep the assets in good working
order so as to minimize disruptions
and downtimes.
Risk Management
To keep the assets in a state of good
repair for the owners’ health and
safety.
PG Department

Risk Management
PG Department
8
07-10-2020

Aesthetic Preservation
To keep the assets
from deteriorating
in appearance
and becoming unsightly.
Responsible Stewardship
To ensure that the assets achieve
their full potential service life.
PG Department

Duty of Care
To satisfy a legislated duty that is
owed to owners, occupants and
guest on the property.
Duty to Mitigate
To prevent unnecessary damage to
assets that may result in their
premature failure.
PG Department
9
07-10-2020
Types Of Maintenance
• Breakdown maintenance
1. Periodic maintenance ( Time
based maintenance - TBM)
2. Predictive maintenance
• Condition Monitoring
PG Department
Break Down Maintenance

• It means that people waits until
equipment fails and repair it.
• Such a thing could be used when
the equipment failure does not
significantly affect the operation
or production or generate any
significant loss other than repair
cost.
PG Department
10
07-10-2020
Preventive maintenance
• It is a daily maintenance (
cleaning, inspection, oiling and
re-tightening ),
• Design to retain the healthy
condition of equipment and
prevent failure through the
prevention of deterioration,
periodic inspection or equipment
condition diagnosis, to measure
deterioration
PG Department
Periodic maintenance
• It is a time based maintenance
• Consists of periodically
inspecting, servicing and cleaning
equipment and replacing parts to
prevent sudden failure and
process problems
PG Department
11
07-10-2020
Predictive maintenance
• This is a method in which the
service life of important part is
predicted based on inspection or
diagnosis, in order to use the
parts to the limit of their service
life
• Compared to periodic
maintenance, predictive
maintenance is condition based
maintenance.
PG Department
Corrective maintenance
• It improves equipment and its
components so that preventive
maintenance can be carried out
reliably.
• Equipment with design weakness
must be redesigned to improve
reliability or improving
maintainability
PG Department
12
07-10-2020
Content
• Definition of periodic inspection
• Factors to be considered in periodic
inspection
• Procedure for periodic inspection
• Sample periodic chart general
purpose of machine
PG Department
Definition of periodic inspection
PG Department
13
07-10-2020

• Work done in maintenance are
1. Lubrication
2. Cleaning of filters
3. Chips removals
4. Tightening of the loose bolts
5. Oil change
PG Department
PG Department
14
07-10-2020
PG Department

• It is helpful maintaining good and
efficient condition of the machine
• If the such work is done repeatedly
at a regular interval then this
process is termed as the periodic
inspection
PG Department
15
07-10-2020

• The maintenance work is required to
be done at an interval of weather in
1. Days
2. Weeks,
3. Quarterly or
4. Half yearly
• Maintenance work is decided on the
basis of the advice given by the
manufacturer the past experience to
industry
PG Department
Factors to be considered in periodic

inspection
1. Age of the machine tools
2. Nature of production
3. Skill of operator
4. Seniority of operation
5. Type of machine tool
6. Repair complexity of machine
tool
PG Department
16
07-10-2020
Factors to be considered in periodic

inspection
7. Repair scheme applicable
8. Total time duration repair
cycle
9. Different stages in adopted
repair cycle
10. Work involved in each stages
11. Criticality of the operation
PG Department
Procedure for periodic inspection

• Section is carried out at various stages of the
work
• Proper charts are utilized to find the faults

and for the inspection
• In this chart the work to be done for the

inspection, lubrication, adjustment and
repairing are clearly mentioned
• By using all this the work will be done

completely
PG Department
17
07-10-2020
Sample periodic chart general purpose of machine

include the following information and details
• Observe machine tool externally and
note down the faults in different units
• Check the condition of machine in
each units by opening the cover
• Clearness of lead screw and split nut,
saddle, carriage
• Interplay of the spindle bearing and
bearing lubrication
• Check the gear engagement and
position of the levers
PG Department
Sample periodic chart general purpose of

machine include the following information and
details
• Check belt tension and adjust it if
found necessary
• Checking and adjust the spring
tension
• To adjust the all machine alignment
PG Department
18
07-10-2020
Content
• Definition of Degreasing
• Different methods for the cleaning
and degreasing
• Requirement of cleaning
PG Department
Definition of Degreasing
• It is the process of removal of
1. Dirt
2. Dust
3. Rust
4. Oil
5. Grease
• From the parts to make them ready
for inspection and measurement of
dimension
PG Department
19
07-10-2020
Definition of Degreasing
PG Department
Different methods for the degreasing and

cleansing
1. Cleaning using petrol, kerosene,
diesel and petrol
2. Thermal cleaning method
3. Cleaning of parts by machine
method
4. Chemical cleaning
5. Abrasive cleaning
PG Department
20
07-10-2020
Cleaning using kerosene, diesel

and petrol
• The machine parts are washed
using
1. Petrol
2. Kerosene
3. Diesel
• Machine parts are dried using cloth
• Universally used method
PG Department
Thermal cleaning method

• The removal of dust, dirt, rust, oil
and grease is done using burning
method
• The dust, dirt , rust , oil and grease
are burnt using the oxy acetylene
flame gas
PG Department
21
07-10-2020
Thermal cleaning method
PG Department
Cleaning of parts by machine method

• The cleaning of dust, dirt, rust, oil
and grease is done using
mechanical equipments like
1. Wire brush
2. Milling cutter
3. Rotary
PG Department
22
07-10-2020
Chemical cleaning
• The grease and oil layer on the parts
of machine is in the form of sticked
layer
• It can be removed using chemical
• The chemical bath machine parts are
done and chemical used are listed
1. Lime
2. Caustic soda
3. Residual oil
PG Department
Abrasive method
• The cleaning is done using hydraulic
sand blaster
• The sand particles are thrown on
the machine parts for the purpose
of cleaning of the surface
PG Department
23
07-10-2020
Abrasive method
PG Department
Requirement of cleaning
• For the inspection of the wornout
parts
• To increase the quality of the repairing
• To obtain the accurate and correct
dimension of the machine parts
• To provide a quality layer of paint so
as to increase the adhesion on the
surface3.
• For better handling of the machine
parts for during their repairs
• Improve the appearance of the parts
PG Department
24
07-10-2020
Content
• Repair scheme
• Overhauling of the mechanical
ocmponents
PG Department
Repair scheme
• The activities involved in the repair
scheme are
1. Inspection [I]
2. Small repair [S]
3. Medium repair [M]
4. Complete overhaul [C]
PG Department
25
07-10-2020
Repair scheme
• The time interval between the two
complete overhaul is termed as total
cycle time
• The time interval between any two
nearby stages is termed as the
inspection time
• The time interval between small
repair and medium repair and
complete overhaul to small repair is
termed as repair time
PG Department
Repair scheme (i)

• This repair cycle consists of many
activities like
• Drilling
• Lathe machine
• Shaping machine
• Cutting machine
• Slotting machine
• Work is done in one shift
• It will take 10 years to complete it
work at an interval of 6 months
PG Department
26
07-10-2020
Repair scheme (i)

• When the repair complexity is upto
30 then such scheme is utilized
• It has 2- medium repairs, 6- small
repairs and 9- inspection
PG Department
Repair scheme (ii)

• The repair cycle time is 6 years
• The interval between the two stages
is 4 months
PG Department
27
07-10-2020
Repair scheme (ii)

• When the repair complexity is more
then such scheme is utilized
• It has 2- medium repairs 6- small
repairs and 27- inspection
PG Department
Repair scheme
• The machine working in two shifts
then repair scheme shift should be
doubled
• For example in repair scheme (i)
work is done is one shift
• If the shift is double then the repair
shift should also be double and the
repairing work will double and
repairing work will also complete in
5 years
PG Department
28
07-10-2020
Mechanical overhauling
• Mechanical components consists of
1. Head stock
2. Tail stock
3. Cross slide
4. Transmission mechanism
5. Gear box
• The assemblies need to dismantle
for their repairing
PG Department
• Factors considered in dismantling the
sub parts of the machine are
1. Disconnect the electric connection of
the machine
2. Drain out all the residual oil form the
unit
3. Don’t apply the hammer stress on the
parts. Provide the wooden block
between the parts
4. Use tools and fixers that do not
damage
PG Department
29
07-10-2020
5. Try not to damage the parts
6. Use only the specified force for
dismantling
7. Always used the necessary supports
8. Decide various groups of different
parts and place them group wise
9. Heavy parts should be placed in
stands
10.Very heavy parts should be placed in
the nearby place of assembly
PG Department
11.Keep the nut and bolts in their
original pair by applying bolts on
their corresponding nuts by
developing the contacts of 2 to 3
threads
PG Department
30
07-10-2020
Electric motor overhauling

• Electric motor are important and
efficient machine
• It requires less maintenance
• At regular time the overhauling is
required to be done otherwise
following can taker place
1. Breakdown
2. Stopping in the production
3. More repairing cost can take place
4. Early replacement of motor can occur
PG Department
Outline
• Definition, need, steps and
advantages of preventive
maintenance.
• Steps / procedure for the periodic
and preventive maintenance of
machine tools
PG Department
31
07-10-2020
Definition of preventive
maintenance
• It is the maintenance which stops
the wear and changes taking
place in the condition of machine
• It is the act of keeping the
machine in good condition and in
the efficient condition for the
longer period of time
PG Department
Need of preventive
maintenance
• To increase the productivity of
the machine
• To reduce the cost of production
• To prevent the occurrence of the
fault
• To repair the fault at the early age
of the fault
• For the quality production
PG Department
32
07-10-2020
Need of preventive
maintenance
• To avoid the obstruction of
working of machine
• To the keep the machine in good
condition
PG Department
Steps involved in preventive

maintenance
• Training of preventive
maintenance to the operator,
fitters
• To prepare the list of item to be
checked
• To form the group of machine and
equipment
• To analyze the breakdown
PG Department
33
07-10-2020
Steps involved in preventive

maintenance
• To get the support from the
management for preventive
maintenance
• To understand the basic idea of
preventive maintenance
• Preparation of maintenance
planning based on the past
records
• To keep the stock of spare parts
PG Department
Advantages of preventive
maintenance
• Reduction in the stoppage time
due to reduced down time of
machine
• Number of costly repairs are
reduced
• Many repairing work will be
carried out at the same time
• The rejection of the output will be
reduced
PG Department
34
07-10-2020
Advantages of preventive
maintenance
• More safety of machine parts and
of workers are found
• Cost of production will be
reduced
• Service life of the machine will be
increased
• The breakdown will also get
reduced
• Wear and tear of the machine will
be reduced
PG Department
Steps / procedure for the periodic and

preventive maintenance of machine tools
• Remove the electrical connection
• Empty the oil from the sump
• Use the tools and fixtures that do
not damage the machine
• Do not damage the part directly
during the machine
• Provide the support if wood
before hammering
PG Department
35
07-10-2020

• Nut and bolts should be kept in
the special tray
• Do not heap up the spare parts
• Place them in the groups
• Heavy parts should be place in
the stand
• Very heavy pats should be placed
in the
PG Department

• Nut and bolts ahould be kept in
the pairs by applying the nuts to
their corresponding bolts
• Inspection
• Give speed and feed to the
mechanism
• Adjust the clearance
• Clear the oil filter and coolant
filter
• Provide oil and grease
PG Department
36
07-10-2020

• Inspection
• Tighten the bolts
• Change the worn-out bolts
• Change the lubrication oil as per
the schedule
PG Department

• Repairing
• Clear the parts which has more
wear
• Keep the predecided clearance
• Repair the oil pockets
• Remove the wear on the guide
surface by guiding
• Paint the machine surface
• Check and repair the machine
foundation
PG Department
37
07-10-2020

• Repairing
• Test the machine completely after
fitting
• Test the machine after every 6
months or after complete
overhauling
PG Department
Outline
pumps
compressor
diesel generator set
PG Department
38
07-10-2020

preventive maintenance of pumps
• Check whether the working of the
pump is as per the need
• Stop the leakage
• Clean the filter
• Regulate the discharge meter
using the manometer
• Tighten the bolts wherever
needed
• Provide the packing required
PG Department

• Repairing
• Replace the worn out teeth and
bearing
• Replace the damage seals
• Finishing work if the gear should
be done
• Scratches on the face of the pump
should be removed
• Replace the worn-out piston
PG Department
39
07-10-2020

• Repairing
• Replace the worn out pipes
• Test the pump and know the
pressure
PG Department

preventive maintenance of compressor
• The air in compressor should be
clean and free form the dust
particles
• Provide the new filter
• Lubricate the compressor as per
the requirement
• Checking of the nut and bolt
should be done
• Adjust the clearance as per the
requirement
PG Department
40
07-10-2020

preventive maintenance of compressor
• Check the defective switch and do
replace it if found
• Check the solenoid and replace it
if found defective
• Checking the water cooling
system
PG Department

preventive maintenance of generator set
• Check the lubrication oil level
• Check the fuel level
• Check the leakage in the fuel tank
• Clean the engine and tighten the
nuts and bolts if required
• Clean all electrical connection
• Lubricate the fuel pump by oiling
PG Department
41
07-10-2020
Outline
• Factors involved in the
formulating the program and
schedule
• Definition of maintenance
scheduling
• Procedure for maintenance
scheduling
• Schedule based on the
maintenance work
• VEIN analysis
PG Department
Factors involved in the

formulating the program and schedule
PG Department
42
07-10-2020

• Importance of the machine
• Availability of the spare parts of
the machine
• Availability of machine
• Availability of the skilled labors
• The number of hours during
which the machine is working the
during the whole day
PG Department

• The stock of the spare parts
• Need of inspection frequency
• The age, condition and working of
the machine
• Repair complexity of the machine
• Policy of the management
PG Department
43
07-10-2020
Definition of maintenance
scheduling
• The scheduling is the procedure
of preparing the time table to
carry out different maintenance
work based upon
1. Production target
2. Receipt of the material
3. Need of manpower
4. Availability of the tool
5. Requirement of service
PG Department
Procedure for maintenance

scheduling
• Decide the standard time
requirement for the maintenance
work
• Only those machine should be
involved in the machine which
can be spared out
• Keep equal work load for the
maintenance work
PG Department
44
07-10-2020

scheduling
• The maintenance work should be
carried out in the recess or in the
holiday
• A flexible time table should be
prepared
• Select the machine for the
repairing and overhauling in
number equal to square capacity
of the machine
PG Department

scheduling
• The schedule should be prepared
in such a way that there should
not be any kind of loss to the
production
PG Department
45
07-10-2020
Schedule based on the

maintenance work
The schedule of the maintenance
work is mention below
1. Emergency work
2. Non emergency work
3. New work
4. Preventive work
PG Department
VEIN analysis
• Here the grouping of the activities
is done according to the utility
and importance
• The machine are divided in the
groups
V Vital machine
E Essential machine
I Important machine
N Normal machine
PG Department
46
07-10-2020
Outline
• Advantages of preventive
maintenance
• Repair cycle concept
PG Department
PG Department
47
07-10-2020
Advantages of preventive maintenance
• Reduction in the production

stoppage
• Reduction in costly repairs
• All the repairing can be done at
the same time
• Rejection of manufactured
product will be less
• Less spare capacity of the
machine is required
PG Department
• Good industrial relation will be

formed
• Unit cost of production will be
reduced
• Machine will not require the
replacement before the intended
time
• Increase in the service life of the
equipment
PG Department
48
07-10-2020
• Increase in the productivity

• Maintenance work will became
effective and result oriented
• Modernization of the machine is
obtained
• Safe atmosphere will be found
PG Department
Repair cycle concept
• For maintaining the good

condition following aims are
required to be achieved
1. Increase the life of the machine
2. Reduce the breakdown
3. Obtain the accuracy
4. Quality product
PG Department
49
07-10-2020
Repair cycle concept
For maintaining good condition and

to achieve the required goals
following stages of work is required
to be done
• Inspection
• Small repair
• Medium repair
• Complete overhaul
PG Department
Inspection
PG Department
50
07-10-2020
Inspection
• It is not just merely checking
• Keeping the observation on
machine
• All activities are performing and
per the description given by the
manufacturer
PG Department
Inspection
Observing the machine by running it at all speed
Adjusting the clearance of coupling, clutch, breaks
Cleaning of oil and coolant
Tightening all bolts
Replacing the worn-out bolts
Replacing the lubrication oil
PG Department
51
07-10-2020
Small repairs
PG Department
Small repairs
• Here each and every maintenance
activities of inspection will be
done
• The repairing work will be
distributed
• The condition of the machine will
be improved
PG Department
52
07-10-2020
Small repairs
All the repairing work should be
carried out as per the schedule
Dismantle two to three units and
clean them
The parts that require repairing
should be repaired
Other parts beyond repairing
should be replaced
Assemble the dismantle repair
pats and run the machine
PG Department
Medium repairs
PG Department
53
07-10-2020
Medium repairs
Maintenance work as per the
inspection and small repairs
should be of
Repairing done first
some additional units
are carried out first
The wear of the guided surface is
improved
Layer of paint should be applied
on
Runthe outer
the surface
machine and testing
should be done as per the
accuracy required
PG Department
Complete Overhaul
PG Department
54
07-10-2020
Complete Overhaul
• It is the last stage of the repair
• The machine is bring back to the
original condition
• It will become capable for
working for the long time
PG Department
Complete Overhaul
All the units are removed
Complete dismantling is done
Each part is completely checked

Repairing and replacement is done
accordingly
The wear on each part is decided on
measuring their dimension & based on
that repairing and replacement is done
PG Department
55
07-10-2020
Complete Overhaul
The assembling of the dismantle parts is done
The clearance distance should be as per the

guidance of manufacturer
The foundation of the machine should

checked and repaired
The scrapping and grinding of the machine

should be done
PG Department
Complete Overhaul
The testing of machine should be done by
running it in all speed
It should be checked in all accuracy
It the job is found as per the quality norms

then it is said to be as OK
If noy then corrective measures are required

to be taken
PG Department
56
07-10-2020
PG Department
57

CH 5 Is Fullnotes

Uploaded by

Copyright:

Available Formats

You might also like

CH 5 Is Fullnotes

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

CH 5 Is Fullnotes

Uploaded by

Copyright:

Available Formats

07-10-2020

Reasons for Maintenance

• Break Down Maintenance

It is a daily maintenance ( cleaning, inspection, oiling and re-tightening

Time based maintenance consists of periodically inspecting,

This is a method in which the service life of important part is

• The key to a successful condition monitoring programme includes:

• Successfully using this programme enables the repair of problem

• Condition monitoring not only helps plant personnel reduce the

Reasons for Maintenance

Reasons for Maintenance

Reasons for Maintenance

Reasons for Maintenance

Break Down Maintenance

Definition of periodic inspection

Definition of periodic inspection

Definition of periodic inspection

Definition of periodic inspection

Definition of periodic inspection

Definition of periodic inspection

Factors to be considered in periodic

Factors to be considered in periodic

Procedure for periodic inspection

• Proper charts are utilized to find the faults

• In this chart the work to be done for the

• By using all this the work will be done

Sample periodic chart general purpose of machine

Sample periodic chart general purpose of

Different methods for the degreasing and

Cleaning using kerosene, diesel

Thermal cleaning method

Thermal cleaning method

Cleaning of parts by machine method

Repair scheme (i)

Repair scheme (i)

Repair scheme (ii)

Repair scheme (ii)

Electric motor overhauling

Steps involved in preventive

Steps involved in preventive

Steps / procedure for the periodic and

Steps / procedure for the periodic and

Steps / procedure for the periodic and

Steps / procedure for the periodic and

Steps / procedure for the periodic and

Steps / procedure for the periodic and

Steps / procedure for the periodic and

Steps / procedure for the periodic and

Steps / procedure for the periodic and

Steps / procedure for the periodic and

Steps / procedure for the periodic and

Steps / procedure for the periodic and

Factors involved in the

Factors involved in the

Factors involved in the

Procedure for maintenance

Procedure for maintenance