Scribd
Upload
102 views

Maintenance Engineering (CH: 2,0) : Instructors: Dr. M. Zeeshan Zahir Engr. Adnan Rasheed

This document discusses different types of maintenance including run-to-failure maintenance, preventive maintenance, corrective maintenance, improvement maintenance, and predictive maintenance. It provides details on each type such as their definitions, advantages, disadvantages, and how they are applied. The document is intended to instruct readers on maintenance engineering principles.

Uploaded by

Minhaj Ullah
Copyright
© © All Rights Reserved
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
102 views

Maintenance Engineering (CH: 2,0) : Instructors: Dr. M. Zeeshan Zahir Engr. Adnan Rasheed

This document discusses different types of maintenance including run-to-failure maintenance, preventive maintenance, corrective maintenance, improvement maintenance, and predictive maintenance. It provides details on each type such as their definitions, advantages, disadvantages, and how they are applied. The document is intended to instruct readers on maintenance engineering principles.

Uploaded by

Minhaj Ullah
Copyright
© © All Rights Reserved
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
You are on page 1/ 25

Maintenance Engineering

(CH: 2,0)

Instructors: Dr. M. Zeeshan Zahir


Engr. Adnan Rasheed

1
Types of Maintenance

• Run to Failure Maintenance (RTF)

• Preventive Maintenance (PM)

• Corrective Maintenance (CM)

• Improvement Maintenance (IM)

• Predictive Maintenance (PDM)


2
Run to Failure Maintenance (RTF)

• The required repair, replacement, or restore action


performed on a machine or a facility after the
occurrence of a failure in order to bring this
machine or facility to at least its minimum
acceptable condition.

• It is the oldest type of maintenance.

3
Run to Failure Maintenance (RTF)
• It is subdivided into two types:
– Emergency maintenance: it is carried out as fast
as possible in order to bring a failed machine or
facility to a safe and operationally efficient
condition.
– Breakdown maintenance: it is performed after
the occurrence of an advanced considered failure
for which advanced provision has been made in
the form of repair method, spares, materials,
labour and equipment.
4
Run to Failure Maintenance (RTF)
• Disadvantages:

1. Its activities are expensive in terms of both direct and


indirect cost.

2. Using this type of maintenance, the occurrence of a failure


in a component can cause failures in other components in
the same equipment, which leads to low production
availability.

3. Its activities are very difficult to plan and schedule in


advance.
5
Run to Failure Maintenance (RTF)
• This type of maintenance is useful in the following
situations:

1. The failure of a component in a system is unpredictable.

2. The cost of performing run to failure maintenance activities


is lower than performing other activities of other types of
maintenance.

3. The equipment failure priority is too low in order to include


the activities of preventing it within the planned
maintenance budget.
6
Preventive Maintenance (PM)

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 conditions.

7
Preventive Maintenance (PM)

British Standard 3811:1993 Glossary of terms


defined preventive maintenance as:

the maintenance carried out at predetermined


intervals or according to prescribed criteria and
intended to reduce the probability of failure or the
degradation of the functioning and the effects
limited.

8
Preventive Maintenance (PM)

• The advantage of applying preventive maintenance


activities is to satisfy most of maintenance
objectives.

9
Preventive Maintenance (PM)
• The factors that affect the efficiency of this type of maintenance:

1. The need for an adequate number of staff in the maintenance


department in order to perform this type of maintenance.
2. The right choice of production equipment and machinery that is
suitable for the working environment and that can tolerate the
workload of this environment.
3. The required staff qualifications and skills, which can be gained
through training.
4. The support and commitment from executive management to the
PM programme.
5. The proper planning and scheduling of PM programme.
6. The ability to properly apply the PM programme.

10
Preventive Maintenance (PM)
• It is good for those machines and facilities which
their failure would cause serious production losses.

• Its aim is to maintain machines and facilities in


such a condition that breakdowns and emergency
repairs are minimised.

• Its activities include replacements, adjustments,


major overhauls, inspections and lubrications.

11
Preventive Maintenance (PM)
• Researchers subdivided preventive maintenance into
different kinds according to the nature of its activities:

• Routine maintenance which includes those maintenance


activities that are repetitive and periodic in nature such as
lubrication, cleaning, and small adjustment.

• Running maintenance which includes those maintenance


activities that are carried out while the machine or
equipment is running and they represent those activities that
are performed before the actual preventive maintenance
activities take place.

12
Preventive Maintenance (PM)
• Opportunity maintenance which is a set of maintenance
activities that are performed on a machine or a facility when
an unplanned opportunity exists during the period of
performing planned maintenance activities to other
machines or facilities.

• Window maintenance which is a set of activities that are


carried out when a machine or equipment is not required for
a definite period of time.

• Shutdown preventive maintenance, which is a set of


preventive maintenance activities that are carried out when
the production line is in total stoppage situation.

13
Corrective Maintenance (CM)
• In this type, actions such as repair, replacement, or
restore will be carried out after the occurrence of a
failure in order to eliminate the source of this
failure or reduce the frequency of its occurrence.

In the British Standard 3811:1993 Glossary of terms,


corrective maintenance is defined as:

the maintenance carried out after recognition and intended


to put an item into a state in which it can perform a required
function.

14
Corrective Maintenance (CM)
• This type of maintenance is subdivided into three
types:

• Remedial maintenance, which is a set of activities


that are performed to eliminate the source of failure
without interrupting the continuity of the
production process.

The way to carry out this type of corrective maintenance is


by taking the item to be corrected out of the production line
and replacing it with reconditioned item or transferring its
workload to its redundancy.
15
Corrective Maintenance (CM)
• Deferred maintenance, which is a set of corrective
maintenance activities that are not immediately
initiated after the occurrence of a failure but are
delayed in such a way that will not affect the
production process.

• Shutdown corrective maintenance, which is a set of


corrective maintenance activities that are performed
when the production line is in total stoppage
situation.

16
Corrective Maintenance (CM)
• The main objectives of corrective maintenance are the
maximisation of the effectiveness of all critical plant systems,
the elimination of breakdowns, the elimination of unnecessary
repair, and the reduction of the deviations from optimum
operating conditions.

• The difference between corrective maintenance and


preventive maintenance is that for the corrective maintenance,
the failure should occur before any corrective action is taken.

• Corrective maintenance is different from run to failure


maintenance in that its activities are planned and regularly
taken out to keep plant’s machines and equipment in optimum
operating condition.
17
Corrective Maintenance (CM)
• The way to perform corrective maintenance activities is by
conducting four important steps:

1. Fault detection.
2. Fault isolation.
3. Fault elimination.
4. Verification of fault elimination.

In the fault elimination step several actions could be taken


such as adjusting, aligning, calibrating, reworking, removing,
replacing or renovation.
18
Corrective Maintenance (CM)
• Corrective maintenance has several prerequisites in
order to be carried out effectively:

1. Accurate identification of incipient problems.


2. Effective planning which depends on the skills of the
planners, the availability of well developed maintenance
database about standard time to repair, a complete repair
procedures, and the required labour skills, specific tools,
parts and equipment.
3. Proper repair procedures.
4. Adequate time to repair.
5. Verification of repair.

19
Improvement Maintenance (IM)
• It aims at reducing or eliminating entirely the need for
maintenance.
• This type of maintenance is subdivided into three types as
follows:

1. Design-out maintenance which is a set of activities that are


used to eliminate the cause of maintenance, simplify
maintenance tasks, or raise machine performance from the
maintenance point of view by redesigning those machines and
facilities which are vulnerable to frequent occurrence of
failure and their long term repair or replacement cost is very
expensive.
20
Improvement Maintenance (IM)

2. Engineering services which includes construction and


construction modification, removal and installation, and
rearrangement of facilities.

3. Shutdown improvement maintenance, which is a set of


improvement maintenance activities that are performed
while the production line is in a complete stoppage situation.

21
Predictive Maintenance (PDM)
• Predictive maintenance is a set of activities that detect
changes in the physical condition of equipment (signs of
failure) in order to carry out the appropriate maintenance
work for maximising the service life of equipment without
increasing the risk of failure.

• It is classified into two kinds according to the methods of


detecting the signs of failure:
– Condition-based predictive maintenance
– Statistical-based predictive maintenance

22
Predictive Maintenance (PDM)

• Condition-based predictive maintenance depends on


continuous or periodic condition monitoring equipment to
detect the signs of failure.

• Statistical-based predictive maintenance depends on


statistical data from the meticulous recording of the
stoppages of the in-plant items and components in order to
develop models for predicting failures.

23
Predictive Maintenance (PDM)
• The drawback of predictive maintenance is that it depends
heavily on information and the correct interpretation of the
information.

• Some researchers classified predictive maintenance as a type


of preventive maintenance.

• The main difference between preventive maintenance and


predictive maintenance is that predictive maintenance uses
monitoring the condition of machines or equipment to
determine the actual mean time to failure whereas preventive
maintenance depends on industrial average life statistics.
24
Types of Maintenance
MAINTENANCE

PLANNED UNPLANNED
MAINTENANCE MAINTENANCE
(PROACTIVE) (REACTIVE)

EMERGENCY BREAKDOWN

PREDECTIVE PREVENTIVE IMPROVEMENT CORRECTIVE


MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE

STATISTICAL CONDITION - DEFERRED REMEDIAL


ENGINEERING DESIGN - OUT
- BASED BASED SERVICES

Shutdown Maintenance

WINDOW RUNNING ROUTINE OPPORTU- SHUTDOWN SHUTDOWN SHUTDOWN


NITY PREVENTIVE IMPROVEMENT CORRECTIVE

25
Figure 2.4 Maintenance
Types

You might also like