ME 403

Maintenance Engineering
(CH: 2,0)

Instructors: Dr. M. Zeeshan Zahir

Engr. Adnan Rasheed
 RUN-TO-FAILURE MANAGEMENT

PREVENTIVE MAINTENANCE MANAGEMENT

ROLE OF MAINTENANCE ORGANIZATION
ELEMENTS OF PM
IMPORTANT STEPS FOR ESTABLISHING A PM
PROGRAM
OPERATIONAL MAINTENANCE
 RUN-TO-FAILURE MANAGEMENT
The logic of run-to-failure management is simple and straightforward. When a machine breaks, fix
it. This ‘‘if it isn't broke, don’t fix it’’ method of maintaining plant machinery has been a major part
of plant maintenance operations since the first manufacturing plant was built, and on the surface
sounds reasonable. A plant using run-to-failure management does not spend any money on
maintenance until a machine or system fails to operate. Run-to-failure is a reactive management
technique that waits for machine or equipment failure before any maintenance action is taken. It
is in truth a no-maintenance approach of management. It is also the most expensive method of
maintenance management. Few plants use a true run-to-failure management philosophy. In
almost all instances, plants perform basic preventive tasks (i.e., lubrication, machine adjustments,
and other adjustments) even in a run-to-failure environment. However, in this type of
management, machines and other plant equipment are not rebuilt nor are any major repairs
made until the equipment fails to operate.
 Major expenses associated with Run-to-Failure Maintenance Management

The major expenses associated with this type of maintenance management are:

1. High spare parts inventory cost

2. High overtime labor costs,

3. High machine downtime, and

4. Low production availability.

Since there is no attempt to anticipate maintenance requirements, a plant that uses true run-to-failure
management must be able to react to all possible failures within the plant. This reactive method of
management forces the maintenance department to maintain extensive spare parts inventories that
include spare machines or at least all major components for all critical equipment in the plant. The
alternative is to rely on equipment vendors that can provide immediate delivery of all required spare
parts. Even if the latter is possible, premiums for expedited delivery substantially increase the costs of
repair parts and downtime required for correcting machine failures.
 Major expenses associated with Run-to-Failure Maintenance Management

To minimize the impact on production created by unexpected machine failures, maintenance

personnel must also be able to react immediately to all machine failures.
•The net result of this reactive type of maintenance management is higher maintenance cost and
lower availability of process machinery. Analysis of maintenance costs indicates that a repair
performed in the reactive or run-to-failure mode will average about three times higher than the
same repair made within a scheduled or preventive mode. Scheduling the repair provides the
•ability to minimize the repair time and associated labor costs. It also provides the means of
reducing the negative impact of expedited shipments and lost production.
 Preventive Maintenance Management
Preventive maintenance (or preventative maintenance) is maintenance that is regularly performed

on a piece of equipment to lessen the likelihood of it failing. It is performed while the equipment

is still working so that it does not break down unexpectedly.

There are many definitions of preventive maintenance, but all preventive maintenance

management programs are time driven.

The actual implementation of preventive maintenance varies greatly. Some programs are

extremely limited and consist of lubrication and minor adjustments. More comprehensive

preventive maintenance programs schedule repairs, lubrication, adjustments, and machine

rebuilds for all critical machinery in the plant. The common denominator for all of these

preventive maintenance programs is the scheduling guideline. All preventive maintenance

management programs assume that machines will degrade within a time frame typical of its

particular classification.
 ROLE OF MAINTENANCE ORGANIZATION

Too many maintenance organizations continue to pride themselves on how fast they can react to

a catastrophic failure or production interruption rather than on their ability to prevent these

interruptions. While few will admit their continued adherence to this breakdown mentality, most

plants continue to operate in this mode. Contrary to popular belief, the role of the maintenance

organization is to maintain plant equipment, not to repair it after a failure. The mission of

maintenance in a world-class organization is to achieve and sustain optimum availability.

•Optimum Availability
•Optimum Operating Condition
•Maximum Utilization of Maintenance Resources
•Optimum Equipment Life 
•Minimum Spares Inventory
•Ability to React Quickly
 Mission of Maintenance in a world-class organization

• Optimum Availability

The production capacity of a plant is, in part, determined by the availability of production systems and their auxiliary
equipment. The primary function of the maintenance organization is to ensure that all machinery, equipment, and
systems within the plant are always on line and in good operating condition.
• Optimum Operating Condition

Availability of critical process machinery is not enough to ensure acceptable plant performance levels. The
maintenance organization has the responsibility to maintain all direct and indirect manufacturing machinery,
equipment, and systems so that they will be continuously in optimum operating condition. Minor problems, no
matter how slight, can result in poor product quality, reduce production speeds, or affect other factors that limit
overall plant performance.
• Maximum Utilization of Maintenance Resources

The maintenance organization controls a substantial part of the total operating budget in most plants. In addition to
an appreciable percentage of the total plant labor budget, the maintenance manager, in many cases, controls the
spare parts inventory, authorizes the use of outside contract labor, and requisitions millions of dollars in repair
parts or replacement equipment. Therefore, one goal of the maintenance organization should be the effective use
of these resources.
 Mission of Maintenance in a world-class organization

• Optimum Equipment Life

One way to reduce maintenance cost is to extend the useful life of plant equipment. The maintenance
organization should implement programs that will increase the useful life of all plant assets.
• Minimum Spares Inventory

Reductions in spares inventory should be a major objective of the maintenance organization. However,
the reduction cannot impair their ability to meet goals 1 through 4. With the predictive
maintenance technologies that are available today, maintenance can anticipate the need for
specific equipment or parts far enough in advance to purchase them on an as-needed basis.
• Ability to React Quickly

Not all catastrophic failures can be avoided. Therefore the maintenance organization must maintain the
ability to react quickly to the unexpected failure.
  
Elements of Preventive Maintenance

Inspection: Periodically inspecting materials/items to determine their serviceability by comparing their

physical, electrical, mechanical, etc., characteristics (as applicable) to expected standards
Servicing: Cleaning, lubricating, charging, preservation, etc., of items/materials periodically to prevent
the occurrence of incipient failures
Calibration: Periodically determining the value of characteristics of an item by comparison to a
standard; it consists of the comparison of two instruments, one of which is certified standard with
known accuracy, to detect and adjust any discrepancy in the accuracy of the material/parameter being
compared to the established standard value 
Testing: Periodically testing or checking out to determine serviceability and detect
electrical/mechanical-related degradation  
Alignment: Making changes to an item’s specified variable elements for the purpose of achieving
optimum performance 
Adjustment: Periodically adjusting specified variable elements of material for the purpose of achieving
the optimum system performance 
Installation: Periodic replacement of limited-life items or the items experiencing time cycle or wear
degradation, to maintain the specified system tolerance
  
CHARACTERISTICS OF A PLANT IN NEED OF A GOOD
PREVENTIVE MAINTENANCE PROGRAM

Some characteristics of a plant in need of a good preventive maintenance program

are as follows:

1.Low equipment use due to failures

2.Large volume of scrap and rejects due to unreliable equipment

3.Rise in equipment repair costs due to negligence in areas such as regular

lubrication, inspection, and replacement of worn items/components

4.High idle operator times due to equipment failures

5.Reduction in capital equipment expected productive life due to unsatisfactory

maintenance
 IMPORTANT STEPS FOR ESTABLISHING A PM PROGRAM

Some of the important steps for establishing a preventive maintenance program are as follow;

• Identify and choose the areas

• Identify the PM needs

• Establish assignment frequency

• Prepare the PM assignments

• Expand the PM program as necessary 

 IMPORTANT STEPS FOR ESTABLISHING A PM PROGRAM

Identify and choose the areas .Identify and selection of one or two important areas to concentrate the
initial PM effort. These areas should be crucial to the success of overall plant operations and may
be experiencing a high degree of maintenance actions. The main objective of this step is to obtain
immediate results in highly visible areas, as well as to win concerned management support.
Identify the PM needs. Define the PM requirements. Then, establish a schedule of two types of tasks:
daily PM inspections and periodic PM assignments. The daily PM inspections could be conducted by
either maintenance or production personnel. An example of a daily PM inspection is to check the
waste water settleable solids concentration. Periodic PM assignments usually are performed by the
maintenance workers. Examples of such assignments are replacing throwaway filters, replacing
drive belts, and cleaning steam traps and permanent filters.
Establish assignment frequency. Establish the frequency of the assignments. This involves reviewing
the equipment condition and records. Normally, the basis for establishing the frequency is the
experience of those familiar with the equipment and the recommendations of vendors and
engineering. It must be remembered that vendor recommendations are generally based on the
typical usage of items under consideration.
Prepare the PM assignments. Daily and periodic assignments are identified and described in detail,
then submitted for approval.
Schedule the PM assignments on annual basis. The defined PM assignments are scheduled on the basis
of a twelve-month period.
Expand the PM program as necessary. After the implementation of all PM daily inspections and
periodic assignments in the initially selected areas, the PM can be expanded to other areas.
Experience gained from the pilot PM projects is instrumental to expanding the program.
 
 OPERATIONAL MAINTENANCE

Operational maintenance is a type of preventative maintenance used to extend the life of

equipment and maximize performance.
Operational maintenance is the care and minor maintenance of equipment using procedures that
do not require detailed technical knowledge of equipment’s or system’s function and design. This
category of operational maintenance normally consists of inspecting, cleaning, servicing,
preserving, lubricating, and adjusting, as required. Such maintenance may also include minor
parts replacement that does not require the person performing the work to have highly technical
skills or to perform internal alignment.
As the term implies, operational maintenance, is performed by the operator of the equipment. Its
purpose is threefold:
(1)to make the operator aware of the state of readiness of the equipment;
(2)to reduce the delays that would occur if a qualified technician had to be called every time a
simple adjustment were needed; and
(3)to release technicians for more complicated work
 OPERATIONAL MAINTENANCE
• This form of preventative maintenance can be performed in any setting where machines, equipment, or
vehicles are used. This may include manufacturing plants and factories, as well as automotive shops. In many
commercial buildings, heating and cooling engineers perform operational maintenance tasks on furnaces,
boilers, and air conditioners.
• Some operational maintenance responsibilities can be as simple as inspecting the machine to spot any
changes or issues. This allows the operator to detect a potential danger, such as loose fasteners or debris
that could contribute to an accident. Basic cleaning, including removing debris or excess grease from a
machine, is also considered part of operational maintenance.
• Depending on the type of equipment in use, operators may also be responsible for replacing worn out filters
or cartridges, or removing and replacing a worn belt, cutting tool, or grinding stone. Operational maintenance
may entail keeping machinery well lubricated to reduce the risk of friction or failure. Many basic machine
adjustments needed during the course of operation also fall within this category of preventative
maintenance.
• Businesses enjoy a number of advantages when they train equipment operators to handle basic maintenance
tasks. As the primary user of the machine, the operator generally knows the unique features and qualities of
that machine better than anyone else, and is better equipped to spot potential problems or changes. By
keeping the machine clean and operating smoothly, he can help reduce accidents and danger to himself and
others. Operational maintenance also reduces the likelihood that the machine will break down, which helps
prevent delays. Finally, by teaching the operator to handle basic tasks, the company can not only save money
on repair bills, but also extend the life of the equipment to cut replacement costs over time.
Thank You