PLANNED

MAINTENANCE
What is Maintenance?
INTRODUCTION
Maintenance

▪ Maintenance, in general, can be defined as

efforts taken to keep the condition and
performance of a machine always like the
condition and performance of the machine
when it is still new.
Objective of Maintenance

▪ Maintenance is the function whose objective is

to ensure the fullest availability of production
equipment, utilities and related facilities at
optimal cost and under satisfactory conditions
of quality, safety and protection of the
environment.

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Importance of Maintenance

▪ Maintenance is an important factor in quality

assurance and in some cases determines the long-
term success of a company. Poorly maintained
resources can cause instability and partially or
completely pause the production. Malfunctioning
machines or complete breakdowns can become a
costly process for most companies.

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Importance of Maintenance

▪ It helps identify the cause of failure

▪ It also helps in deciding the type of maintenance and
maintenance decision like replace and repair
▪ It provides necessary information about the life and
reliability of equipment.
▪ With the help of this tool spare parts management got
initiated.

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Types of Maintenance

MAINTENANCE

PLANNED UNPLANNED
MAINTENANCE MAINTENANCE

Preventive Corrective Proactive Predictive Breakdown

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PLANNED MAINTENANCE

▪ Planned maintenance refers to any maintenance

activity that is planned, documented, and scheduled.
The aim of planned maintenance is to reduce
downtime.
▪ Planned maintenance is maintenance that is organized
and carried out with thought to the future, control and
recording in accordance with the plans that have been
determined previously. 8
Benefits of Planned Maintenance

▪ Reduced production downtime due to fewer unexpected

machine breakdowns
▪ Planned, or anticipated, equipment shut down can be
strategically worked into production planning to minimize
impact on production schedules.

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Benefits of Planned Maintenance

▪ Replacement parts can be properly budgeted and

planned for in advance.
▪ Costs are decreased significantly. Ultimately the
cost of an unexpected failure is comprised of not
only the price of the parts themselves, but also in
labor costs, lost production time and possibly
missed delivery dates. With a planned
maintenance, you can avoid all of that.
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TYPES OF PLANNED
MAINTENANCE
PREVENTIVE
MAINTENANCE
Preventive Maintenance

▪ It is a set of activities that are performed on

plant equipment, machinery and systems
before the occurrence of a failure in order to
protect them and to prevent or eliminate any
degradation in their operating activities.

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Types of Preventive Maintenance
▪ Running maintenance
▫ Includes those maintenance activities that are carried
out while the machine or equipment is running
▪ Scheduled Maintenance
▫ Is any repair and upkeep work performed within a set
time frame.
▪ Shutdown Maintenance
▫ Performed while the equipment is not in use.
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Benefits of Preventive Maintenance

▪ Prolonged productive life of company equipment

▪ Less unplanned downtime caused by equipment failure
▪ Less unnecessary maintenance and inspections
▪ Improved reliability of equipment
▪ Safety
▪ Better Quality Products

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CORRECTIVE
MAINTENANCE
CORRECTIVE MAINTENANCE

▪ It is the maintenance carried out to restore the

unserviceable equipment that has stopped
working to acceptable standards.
Prerequisites of Corrective Maintenance

▪ Existence of fulltime maintenance planner

▪ Properly skilled craftsmen to complete the repair
▪ Standard maintenance procedure for recurring repairs and
maintenance tasks
▪ Allowing sufficient time to maintenance amidst tight
production schedules and management constraints
▪ A thorough verification process to ensure the completion of
repair
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Advantages of Corrective Maintenance

▪ Lower short term cost

▪ Minimal Planning required
▪ Simpler process

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Disadvantage of Corrective Maintenance

▪ Breakdown generally occurs inappropriate times

leading to poor and hurried maintenance
▪ Excessive delay in the production and reduces output
▪ Faster plant deterioration
▪ More spoilt materials
▪ Increase chances of accidents

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PROACTIVE
MAINTENANCE
Proactive Maintenance

▪ A proactive approach to maintenance involves

anticipating and resolving underlying problems
that can cause mechanical failure before it can
occur.

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Benefits of Proactive
Maintenance
Benefits of Proactive Maintenance

▪ Proactive Maintenance Prevents Outages

▫ Unplanned outages are extremely costly for industrial
facilities.
▪ Proactive Maintenance Increases Safety
▫ Safety is a major concern at industrial facilities and
protecting employees and company resources from potential
dangers associated with equipment failure is of vital
importance.

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Benefits of Proactive Maintenance

▪ Proactive Maintenance Maximizes Equipment Life

▫ Purchasing industrial equipment is a significant investment
of resources, making it extremely important to protect this
investment by keeping the equipment running at peak
performance levels for as long as possible.
▪ Proactive Maintenance Lowers Overall Costs
▫ Some companies may be hesitant to implement a proactive
maintenance approach because of the perceived upfront
cost associated with doing so.

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PREDICTIVE
MAINTENANCE
Predictive Maintenance

▪ Predictive maintenance periodically monitors

equipment based on the analysis of data
collected through monitoring or on-site
inspections.

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Benefits of Predictive
Maintenance
Benefits of Predictive Maintenance

▪ Reduction in machine failures

▫ Regular monitoring of the actual conditions of the equipment
and process systems can reduce the number of unexpected
and catastrophic equipment failures
▪ Reduced downtime for repairs
▫ Predictive maintenance reduces the actual time required to
repair or recondition plant equipment.

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Benefits of Predictive Maintenance

▪ Reduced stock of spare parts

▫ The ability to pre-determine defective parts needing repair,
tools and required labor skills ensure a reduction in both
repair time and costs.
▪ Increased service life of parts
▫ Preventing catastrophic failures and early detection of
machine and system problems increase the service life of
industrial plant machinery

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7 Steps of Planned
Maintenance
1. Evaluate the current condition of the equipment

▪ Learn the function, structure, and principle of the

equipment
▪ Identify apparent and minor defects and rectify
▪ Analyze reasons for failures
▪ Sort of our reasons for failures
▪ Prepare malfunction map and preventive
maintenance map.
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2. Improve the Conditions

▪ Eliminate Forced Deterioration

▪ Clarify spots that require and cleaning and lubrication
to maintain equipment function
▪ Update “ cleaning is inspecting “ and lubrication routes
for autonomous maintenance counterparts to cover
any new items.
▪ Improve equipment condition
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3. Preventive Maintenance Inspection Standards

▪ Improve any standards that are lacking, and improve

any unclear points.
▪ Clarify the division of responsibility with
Autonomous Maintenance counterparts.
▪ Record how long each task takes to execute
▪ Record any work that is difficult and why it is
difficult.
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4. Extend Service Life

▪ Analyze malfunction map, PM task and Mean Time

Between Failure (MTBF)
▪ Failures are corrected using Root Cause Failure Analysis
and 5 Why Analysis
▪ Improvement items are classified under reliability,
maintainability, autonomous maintainability, operability
and safety. Results are proposed as maintenance
prevention information. 35
▪ Maintenance skills and training are identified
▪ Preparation of maintenance calendar
▪ Exchange of information between parts
model SGA and Autonomous Maintenance
SGA.

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5.Improvement of Inspection and Maintenance Efficiency

▪ Accurate inspection and improvement in the ease of

its execution
▪ Research on symptoms of deterioration and use of
research results as a measurement indicator.
▪ Machine –specific training to reduce breakdown
repair time.
▪ Review of maintenance standards and calendar.
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6. Implement Quality Maintenance

▪ Identify the relationship between equipment conditions

and quality.
▪ Determine conditions for preventing quality defects, and
execute the improvement of equipment and maintenance
methods to meet the goal of zero quality defects.
▪ Prepare and improve maintenance standards that
guarantee defect-free operation.

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7. Implement CBM

▪ Prediction Maintenance time for priority parts

▪ Research and utilization of equipment diagnosis
function
▪ Research adding self-diagnostic functions to
equipment.

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