University of Hafr Al Batin

Maintenance Engineering
ME 424
BY
Dr. Wajid Ali Khan
Lecture # 05
Maintenance Types
Chap 04 Ben Daya
 Objectives
• Maintenance Actions
• Preventive maintenance
• Corrective maintenance
• Other types of maintenance
 Corrective Maintenance
• Corrective or Breakdown maintenance implies that
repairs are made after the equipment is failed and can
not performing its normal function anymore.

• Quite justified in small factories where:

• Down times are non-critical and repair costs are less than
other type of maintenance
• Financial justification for scheduling are not felt
 Corrective Maintenance
• 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.
 Corrective Maintenance
• 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.
 Corrective Maintenance
• 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.
 Corrective Maintenance Actions
• 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.
 Corrective Maintenance Actions
• 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.
 Corrective Maintenance Actions
• Corrective maintenance actions are actions carried out
after fault recognition and are intended to put a failed
item into a working state to perform its normal
function.
• Immediate CM is corrective maintenance which needs
to be carried out immediately after fault detection.
• Deferred CM is corrective maintenance which is not
immediately carried out after fault detection but is
delayed in accordance with given maintenance rules
 Disadvantages
• Breakdown generally occurs inappropriate times
leading to poor and hurried maintenance
• Excessive delay in production & reduces output
• Faster plant deterioration
• Increases chances of accidents and less safety for both
workers and machines
• More spoilt materials
• Direct loss of profit
• Can not be employed for equipments regulated by
statutory provisions e.g. cranes, lift and hoists etc
 Design Out Maintenance
• Design out maintenance (DOM) deals with redesigning
a part of an object.
• Failure is viewed in a positive sense, as it presents an
opportunity to improve equipment reliability and
advance technology.
• The UH‐60A Black Hawk utility helicopter requires only
2.5–3 man‐hours of maintenance per flight hour at the
unit level, as opposed to 12–20 hours for the family of
helicopters it replaced.
 Time
• Uptime
• Down time
• Repair time
 Maintenance Of Products
• Type A: Standard consumer products;
• Type B: Industrial and commercial products;
• Type C: Defense products.
 Repair Crew Size
• Problem:
• A factory has 200 machines and the maintenance
engineer supervises the repair crews who repair
malfunctioning machines. The maintenance policy is to
repair the broken down machine and bring back in
production within 2 hours on the average. If average
breakdown rate is 3.5 machines/hour and each repair
crew can repair 0.25 machine per hour on the average.
How many repair crews are required ?
 Repair Crew Size
The formula for average repair rate () is
1
ts = ---------- or  =  + 1/ ts
-
Where  = repair rate
 = arrival rate of malfunctioning machines
ts = average time arrivals in the system

Required average repair rate

 = 3.5 + 1 / 2 = 4 machines / hour
No. of Crews =   machines/hour a crew can repair
= 4  0.25 = 16 repair crews required
 Run to Failure
• 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.
 Run to Failure
• 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.
 Run to Failure
• 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.
 Review
What are the characteristics of condition‐based maintenance
actions?
What is the difference between design out and design for
maintenance?
What are the main issues in the maintenance of consumer
products?
What are the main issues in the maintenance of plants?
Explain the complexity of infrastructure maintenance issues.
What are the main elements of an effective maintenance
framework? Can effective maintenance be achieved without one
of these elements?
Justify the need for a multi‐disciplinary approach to maintenance