ME 403

Maintenance Engineering
(CH: 2,0)

Instructors: Dr. M. Zeeshan Zahir

Engr. Adnan Rasheed
CORRECTIVE MAINTENANCE

CORRECTIVE MAINTENANCE TYPES

CORRECTIVE MAINTENANCE STEPS, DOWNTIME COMPONENTS

REDUCTION IN CORRECTIVE MAINTENANCE TIME

COST OF FAILURE
 CORRECTIVE MAINTENANCE

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 not greater than preventative maintenance.
Corrective Maintenance activity may consist of repair, restoration or
replacement of equipment.
This activity will be the result of a regular inspection, which identifies
the failure in time for corrective maintenance to be planned and
scheduled, then performed during a routine maintenance shutdown.
 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.
In other instances, a poorly maintained system can require repairs as a
result of insufficient preventive maintenance
And in some situations people may opt to focus on corrective, rather than
preventive, repairs as part of a maintenance strategy.

The process of corrective maintenance begins with the failure and a

diagnosis of the failure to determine why the failure appeared.
The diagnostic process can include a physical inspection of a system, the use
of a diagnostic computer to evaluate the system, interviews with system
users, and a number of other steps.
It is important to determine what caused the problem in order to take
appropriate action, and to be aware that multiple failures of components or
software may have occurred simultaneously.
 CORRECTIVE MAINTENANCE

The next step is replacement of damaged components or software.

In some cases, the damage may be repairable, either in situ or by removing
the item in question and doing repairs off site.
In other instances, full replacement with a new item may be required to
restore the system's functionality. For example, if an optical drive in a
computer fails, a technician may determine that replacing part of the drive or
repairing part of it may be sufficient, or may find that the entire drive needs to
be scrapped so that a new one can be inserted.

After the corrective maintenance is performed, a technician verifies that the

fix has worked by testing the system.
This may be done in several stages to confirm that the system is operational
slowly before overloading it with tasks.
Verification is especially important on systems sent in to a facility for repair,
as the technicians want to be sure that when they are sent back out, the users
will be happy with the standard of the work performed.
 CORRECTIVE MAINTENANCE

For some older systems, it may make more sense to rely on

corrective maintenance.
Preventive maintenance can be expensive, and with these systems, it
may not make sense; it may be more cost effective to simply repair
system components as they go wrong.
By contrast, with a newer system, preventive maintenance can save
money in the long term and extend the life of the system by preventing
system failures as much as possible before they happen.
 CORRECTIVE MAINTENANCE TYPES
Corrective maintenance may be classified into five major categories
these are: fail-repair, salvage, rebuild, overhaul, and servicing. These
categories are described below.

1. Fail-repair: The failed item is restored to its operational state.

2. Salvage: This element of corrective maintenance is concerned with
disposal of non-repairable material and use of salvaged material from
non-repairable equipment/item in the repair, overhaul, or rebuild
programs.
 CORRECTIVE MAINTENANCE TYPES
3. Rebuild: This is concerned with restoring an item to a standard as
close as possible to original state in performance, life expectancy,
and appearance. This is achieved through complete disassembly,
examination of all components, repair and replacement of
worn/unserviceable parts as per original specifications and
manufacturing tolerances, and reassembly and testing to original
production guidelines.

4. Overhaul: Restoring an item to its total serviceable state as per

maintenance serviceability standards, using the “inspect and repair
only as appropriate” approach.

5. Servicing: Servicing may be needed because of the corrective

maintenance action, for example, engine repair can lead to
crankcase refill, welding on, etc. Another example could be that the
replacement of an air bottle may require system recharging.
 CORRECTIVE MAINTENANCE STEPS, DOWNTIME COMPONENTS

 Different authors have laid down different sequential steps for

performing corrective maintenance. For example, an author
presents nine steps (as applicable):
 localize, isolate, adjust, disassemble, repair, interchange,
reassemble, align, and checkout.
 Another presents seven steps (as applicable):

 localization, isolation, disassembly, interchange, reassemble,

alignment, and checkout.
 CORRECTIVE MAINTENANCE STEPS, DOWNTIME COMPONENTS

 For our purpose, we assume that

corrective maintenance is
composed of five major
sequential steps, as shown in
Fig. These steps are:

 fault recognition, localization,

diagnosis, repair, and checkout.

FIGURE Corrective maintenance sequential steps.

 CORRECTIVE MAINTENANCE STEPS, DOWNTIME COMPONENTS

 The major corrective maintenance downtime components are

Active repair time, administrative and logistic time, and delay time.
 
 The active repair time is made up of the following subcomponents:
 
1. Preparation time
2. Fault location time
3. Spare item obtainment time
4. Fault correction time
5. Adjustment and calibration time
6. Checkout time
 Reduction in corrective maintenance time
 Reduction in corrective maintenance time is useful to improve maintenance
effectiveness. Some strategies for reducing the system-level corrective
maintenance time are as follows.
 
1. Efficiency in fault recognition, location, and isolation: Past experience
indicates that in electronic equipment, fault isolation and location consume
the most time within a corrective maintenance activity. In the case of
mechanical items, often the largest contributor is repair time. Factors such
as well-designed fault indicators, good maintenance procedures, well-
trained maintenance personnel, and an unambiguous fault isolation
capability are helpful in lowering corrective maintenance time.
2. Effective interchangeability: Good physical and functional interchangeability
is useful in removing and replacing parts/items, reducing maintenance
downtime, and creating a positive impact on spares and inventory needs.
 Reduction in corrective maintenance time

3. Redundancy: This is concerned with designing in redundant parts that

can be switched in at the moment of need so the equipment/system
continues to operate while the faulty part is being repaired. In this case
the overall maintenance workload may not be reduced, but the
equipment /system downtime could be impacted significantly.
4. Effective accessibility: Often a significant amount of time is spent
accessing the failed part. Proper attention to accessibility during design
can help reduce part accessibility time and, in turn, the corrective
maintenance time.
5. Human factor considerations: Attention paid to human factors during
design in areas such as readability of instructions, size, shape, and weight
of components, selection and placement of dials and indicators, size and
placement of access, gates, and readability, and information processing
aids can help reduce corrective maintenance time significantly.
 COST OF FAILURE

Unplanned downtime cost variables:

1.Lost revenue during downtime - especially critical if the plant is running at or
near capacity, or in highly competitive markets. Measured in dollars per hour.
2.Lost revenue due to loss of customer confidence - how many customers will
leave you.
3.Replacement cost of damaged electrical or production equipment
4.Repair costs, especially labor
5.Cost of scrap
6.Cost to clean and restart production
7.Insurance premium reductions
Thank You