TYPES OF

MAINTENANCE
PROGRAM
PRESENTED BY GROUP 3
WHY DO WE NEED A
MAINTENANCE PROGRAM?
The idea behind maintenance planning is to ensure
that you can sustain the proper working condition
of your equipment. While an ordinary plan will get
the job done, any facility requires an effective
program to enjoy the full benefits of your
maintenance policy.
• Safety and Compliance
• Reliability and Sustainability
• Cost-saving
IMPORTANCE OF
MAINTENANCE
PROGRAM
By maintaining such equipment, It
keeps operating efficiently,
increases the safety of your
employees, and helps you avoid
large and costly repairs down the
road.
Different types of
Maintenance
Program
REACTIVE
MAINTENANCE
This involves responding to equipment
malfunctions or breakdowns after they
occur in order to restore the asset to
normal operating condition.

It also takes less time and money to

have equipment repaired when needed.
TYPES OF REACTIVE
MAINTENANCE
BREAKDOWN MAINTENANCE
Breakdown maintenance refers to action
taken on a piece of equipment that won’t start
or operate whatsoever. The machinery is
completely broken, and may require
extensive repairs to run again (or may need to
be replaced entirely). "Unexpected" or
"Urgent"
TYPES OF REACTIVE
MAINTENANCE
RUN-TO-FAILURE MAINTENANCE
Run-to-failure maintenance is deliberately allowing a
machine to run until it breaks down. After the failure,
reactive maintenance is performed—no prior or
preventive maintenance is performed on the machine
in advance.

A very simple example of run-to-fail maintenance is

allowing a light bulb to burn out before worrying
about replacing it
TYPES OF REACTIVE
MAINTENANCE
CORRECTIVE MAINTENANCE
Any type of action that targets and
repairs a system malfunction so that
equipment can be restored to proper
working order.
TYPES OF REACTIVE
MAINTENANCE
EMERGENCY MAINTENANCE
Emergency maintenance requires a last-
minute response to the sudden
breakdown of an asset. However,
emergency maintenance entails some
type of threat to health and safety. (e.g.
safety locks fail on a machine with
hazardous moving parts)
BENEFITS OF REACTIVE MAINTENANCE

1. LOWER 2. FEWER 3. NO
UPFRONT STAFF PLANNING
COSTS MEMBERS TIME
NEEDED NECESSARY
DISADVANTAGES OF REACTIVE MAINTENANCE

1.UNPREDIC- 2.UNEXPEC- 3. OVERTIME

TABLE TED FOR
BUDGET EQUIPMENT RELEVANT
DOWNTIME EMPLOYEES
DISADVANTAGES OF REACTIVE MAINTENANCE

4. SHORTER 5. HIGHER
EQUIPMENT ENERGY
LIFE COSTS
EXPECTANCY
 HOW MUCH DOES
REACTIVE
MAINTENANCE COST
TO IMPLEMENT?
The costs associated with reactive maintenance vary greatly, depending on the scope of repairs
needed and the value of the item in question.
EXAMPLES OF REACTIVE MAINTENANCE

1. A school’s HVAC unit breaks down unexpectedly.

2. A bearing is overheating inside a machine

3. A forklift is not raising or lowering properly.

4. A restaurant’s dishwasher isn’t properly cleaning dishware and utensils.

5. A treadmill at the gym is malfunctioning.

 PREVENTIVE
MAINTENANCE
REPORTER: DOLLENTE, ROWEL
PREVENTIVE MAINTENANCE
SUMMARY
•Preventive maintenance
•Objective
•Equipment to inspect.
•Frequency of inspection
•Advantages
•Disadvantages
•TYPES OF PREVENTIVE
MAINTENANCE
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE IS ONE OF THE FOUR TYPES OF
MAINTENANCE.

PREVENTIVE MAINTENANCE PREVENTS BREAKDOWN BY:

1.TIMELY INSPECTION 3. ADJUSTMENT

2. LUBRICATION 4.REPAIR.
PREVENTIVE MAINTENANCE
·MAINTENANCE CARRIED OUT BEFORE BREAKDOWN
OCCURS.

·MINIMIZE PROBLEMS OF BREAKDOWN MAINTENANCE

• EXCESSIVE DELAY IN PRODUCTION
2. Time loss
3. Productivity loss
PREVENTIVE MAINTENANCE
MAINTENANCE ENGINEER LOCATES WEAK SPOTS.
1.Bearing
2.Parts under vibration
3.Parts under high temperature

·REDUCING THE DANGER OF BREAKDOWN

1.Inspect and repair.
OBJECTIVE
·Locating any condition which may lead to a breakdown.
·Periodic inspection of components and correct them in
minor stage
·To make machinery and equipment always ready to use
and maintain their optimum productivity efficiency.
·To achieve maximum productivity by the minimum
repair cost and ensure the safety of the workers.
 01 APPLICATION OF PREVENTIVE

THE MAINTENANCE TO ALL THE ITEMS IS

NOT NECESSARY.

EQUIPMENT 02 THERE ARE CERTAIN ITEMS THAT ARE MORE

ESSENTIAL FOR CONTINUING PRODUCTION
THAN OTHERS

TO INSPECT 1.Process equipment

2.Material handling equipment
3.Safety equipment
HOW TO PROPERLY INSPECT
EQUIPMENTS
THE 01 THE FREQUENCY OF INSPECTION CAN BE
DECIDED BY PAST DATA.

FREQUENCY 1. Created by the number of experiments.

OF
02 BASIS OF COST AND SAVING OF THE
PREVENTIVE MAINTENANCE PROGRAM
1. If the cost is very high, then reduce the

INSPECTION
frequent inspection

03 REQUIRED TO INSPECT FREQUENTLY –

EQUIPMENT THAT IS SUBJECTED TO:

• Vibration 4. Fatigue Stress

HOW OFTEN DO WE INSPECT • Overloading 5. Stress
• Exposure to Dirt 6. Corrosion
WHAT ARE THE
ADVANTAGES?
01 Reduce breakdown and repair time.

02 Low Maintenance cost

03 Better production quality and lower unit cost of manufacture

04 The chance of accidents is reduced

05 No delay in delivery product

WHAT ARE THE
DISADVANTAGES?
The cost of preventive maintenance is high due to regular
01
inspection of equipment.
Preventive maintenance required more workers compared to
02
breakdown maintenance.

03 Leads to over maintenance and loss of money.

 TYPES OF PREVENTIVE
MAINTENANCE
CONDITION-
RISK-BASED FAILURE
TIME-BASED BASED
MAINTENANCE FINDING
MAINTENANCE MAINTENANCE
(RBM) MAINTENANCE
(CBM)
RISK BASED MAINTENANCE
RBM refers to
maintenance tasks that
are performed
depending on the level
of risk an asset poses
in the event of failure.
FAILURE -FINDING MAINTENANCE
This type of preventive
maintenance focuses on
detecting potential hidden
failures of assets that
perform protective
functions.
TIME-BASED MAINTENANCE
TBM refers to
maintenance tasks that are
performed at fixed
intervals regardless of the
asset’s condition.
Condition-Based Maintenance
CBM focuses on a piece
of equipment that is in the
process of failing or
indicating an impending
failure.
 PREDICTIVE
MAINTENANCE
WHAT IS
PREDICTIVE
MAINTENANCE?
·One of the types of maintenance
·Monitor the condition and performance of
equipment during normal operation.
·Maintenance managers and technicians can
identify possible defects and fix them before they
result in failures.
WHAT IS PREDICTIVE
MAINTENANCE?
· Like preventive maintenance, predictive maintenance is a
proactive strategy that aims to eliminate assets breakdown.
· But unlike preventive maintenance, predictive
maintenance tries to predict when equipment might fail
with the use of IOT (internet of things) and sensors.
· Allows maintenance frequency to be as low as possible to
avoid a costly reactive strategy.
HOW DOES IT
WORK?
·The first step in practicing predictive
maintenance is establishing baseline.
1.Monitor the assets conditional baseline and
collect data.

·Predictive maintenance must be paired with the

right condition – monitoring technology.

1.CMMS (computerized maintenance

management system)
2.IOT – enabled devices.
 HOW DOES IT
WORK?
The IOT (internet of things) plays a key role in the
process of forming an efficient predictive
maintenance strategy.
• Sensors – data – cloud analytic tools – data
visualization – maintenance management

Work order is generated in your CMMS and

assigned to technicians. So, they can perform any
required repairs to address the anomaly.
• Sensors – Predictive maintenance protocol
HOW DOES IT
WORK?
HOW DOES IT WORK?
·Can vary depending on your equipment and
machines.

1.Infrared imagery – to detect high

temperatures components.
2.Acoustic analysis – to detect leak.
3.Vibration sensor – to detect increase and
decrease of vibration.
4.Oil analysis – check the condition of
machines oil lubricant and determine if it
has been compromised by other particles
and contaminants.
THE ADVANTAGES
• Minimizes unplanned downtime of
mission – critical assets.
• Reduces time spent in maintenance.
• Increase the life expectancy of
machines and equipment.
• Reduces machine breakdowns and
unexpected failures.
• Reduces stock of spare parts due to
increased services life of assets.
• Improves safety workplace for
technicians and operators.
 THE DISADVANTAGES
1.Detailed and time-consuming
plan.
2.Purchasing the right
monitoring equipment which
result in high upfront costs.
3.Hiring skilled staff or training
maintenance teams can be
expensive.
STEPS FOR ESTABLISHING A PREDICTIVE MAINTENANCE PROGRAM
PREVENTIVE MAINTENANCE
PREDICTIVE MAINTENANCE
 Corrective
MAINTENANCE
REPORTER: HIMAN, ERWIN
WHAT IS
CORRECTIVE
MAINTENANCE?
Corrective maintenance, also
known as breakdown maintenance
or run-to-failure maintenance.
 EMERGENCY
REPAIRS
Urgent repairs that must be done immediately to
prevent a breakdown. For example, fixing a
subway door that won’t close, which forces service
to stop.
 SERVICE
OUTAGES
Restoring services that are down,
such as fixing a broken
telephone line.
 REPAIRS
Repairing things that are broken,
such a burst water pipe
WHEN IS THE RIGHT
TIME TO USE
CORRECTIVE
MAINTENANCE?
 WHEN NON-CRITICAL
ASSETS ARE
INEXPENSIVE AND EASY
TO REPAIR OR REPLACE

WHEN A SYSTEM HAS

REDUNDANCIES THAT
ALLOW IT TO OPERATE
PROPERTY EVEN IF A
PART FAILS.
WHEN ASSET FAILURE
DOESN’T AFFECT
EQUIPMENT SAFETY
ADVANTAGES
LOWER SHORT-TERM
COST

Corrective maintenance only occurs

as needed, meaning no extra
maintenance costs until a problem
arises
ADVANTAGES
MINIMAL PLANNING
REQUIRED

Since this is sometimes done in

minor problems, you don't have to
fully plan before executing the
repair
DISADVANTAGES
UNPREDICTABILITY

Since equipment is not

monitored after purchase,
failure is highly unpredictable.
DISADVANTAGES
POTENTIALLY REDUCE THE
USEFUL LIFE OF ASSETS

Lack of periodic preventive

maintenance can cause parts to
wear out faster.
DISADVANTAGES
HIGHER LONG-TERM COSTS

When major equipment failure

happens, downtime can be extremely
costly, eroding the organization’s
reputation, customer satisfaction and
security.
 Reliability
MAINTENANCE
Centered
WHAT IS RELIABILITY
CENTERED
MAINTENANCE?
 RELIABILITY CENTERED
MAINTENANCE

Reliability-Centered
Maintenance (RCM) is a
corporate-level maintenance
strategy designed to optimize
maintenance programs by
establishing safe minimum
levels of equipment upkeep.
PRINCIPLES RELIABILITY CENTERED
MAINTENANCE

• Preserve system functions.

• Identify failure modes that can affect system

functions.

• Prioritize identified failure modes according to

risk and cost projections.

• Select the most effective tasks to control failure

modes.
THE REQUIREMENTS OF RELIABILITY-CENTERED
MAINTENANCE.

DECISION
What functions does it perform, and what are
the desired performance standards?

In what ways could the asset fail to fulfill its

functions?

What are the causes of each possible failure

scenario?
THE REQUIREMENTS OF RELIABILITY-CENTERED
MAINTENANCE.

ACTION
What should we do if we can’t
determine a suitable proactive
task?
 HOW TO
INITIATE RCM?
REPORTER: MANALAC, ALDRIN
 SELECTION OF
01 EQUIPMENT FOR
RCM ANALYSIS

DEFINE THE BOUNDARIES

S T EP S O N 02 AND FUNCTION OF THE

SYSTEMS THAT CONTAIN

HOW T O THE SELECTED

EQUIPMENT

INIT I AT E
DEFINE THE WAYS IN

R C M ? 03 WHICH THE SYSTEM CAN

FAIL (FAILURE MODES)
 IDENTIFY THE ROOT
04 CAUSES OF THE
FAILURE MODES

S T EP S O N 05
ASSESS THE EFFECTS OF
FAILURE

HOW T O • FAILURE MODES AND EFFECTS

ANALYSIS (FMEA)

INIT I AT E • Failure, mode, effect and criticality analysis

• Hazard and operability studies (HAZOPS)
• Fault tree analysis (FTA)

R C M ? • Risk-based inspection (RBI)

 SELECT A MAINTENANCE
06 TACTIC FOR EACH
FAILURE MODE
• CONDITION-BASED

S T EP S O N MAINTENANCE
• TIME OR USAGE-BASED

HOW T O PREVENTIVE MAINTENANCE

INIT I AT E IMPLEMENT AND THEN

REGULARLY REVIEW THE
07
R C M ? MAINTENANCE TACTIC
SELECTED
The bo t t o m l i n e : t h e
impac t o f re l i a b i l i t y
centered
m a i n t e n a n c e
THANK
YOU!