PRINCIPLES OF MAINTANANCE
Maintenance is a set of processes and practices that aim to ensure the continuous
and efficient operation of machinery, equipment, and other types of assets.
Maintenance is concerned with day to day problem of
keeping the machinery, equipment in good operating condition.
It covers all the activities undertaken to keep equipment in a
particular condition or return it to such condition.
Any action that restores failed units to an operational
condition or retains non failed units in an operational state
Maintenance: All activities necessary to keep a system and
all of its components in working order, i.e to maintain the
capability of the system while controlling the costs.
Failure: Any deviation or change in the production system
from its satisfactory condition to a condition below acceptable
or operating standards.
Components of cost:–
i. Cost of maintenance labor and materials
ii. Cost of production loss
Maintenance can be:
Repairs which refers to the activities that are initiated when
equipment has already malfunctioned or failed. Repairs are
usually reactive and may include tasks such as:
i. Diagnosing underperforming machinery
ii. Fixing malfunctioning equipment
iii. Replacing faulty components
iv. Conducting emergency repairs
v. Minimizing downtime when equipment fails
service is a set of tasks, activities, or actions performed to keep
equipment, machinery, systems, facilities, or assets in proper working
condition and to prevent issues, failures, or deterioration.
Replacement of parts is an interchangeable part that is kept in an
inventory and used for the repair or replacement of failed units.
Spare parts are components designed to replace a specific part of a
product that has failed or worn out. They are used to restore an item to its
original condition or functionality. For example, if a car's alternator fails, a
replacement alternator would be installed to replace the faulty one.
Maintenance Objectives
i. To increase functional reliability of production facilities.
ii. To maximize life of equipment.
iii. To maximize production capacity .
iv. To achieve quality product or services by well operated
equipment's.
v. To minimize interruptions in operations.
vi. To minimize breakdowns.
vii. To enhance manpower safety.
viii. To decrease production cost
Reliability is an ability of an item to perform a required function under
given conditions for a given time interval.
Asset management represents all actions an organization takes to
manage assets throughout their lifecycle — from planning a purchase
to asset disposal.
Reliability is a subset of asset management and refers to the tactics
used to maximize the equipment’s reliability and availability, given the
conditions in which it works.
Maintenance is again a subset of reliability, referring to the day-to-day
tasks of fixing and maintaining assets to improve equipment
reliabilityand performance
Importance things to consider before doing maintenance
Time
Spare parts availability
Skilled Labour (knowledge)
TYPES OF MAINTENANCES
Based on planning there are two types of maintenances
Planned maintenance refers to a maintenance process that details
which resources will be needed to solve a particular equipment
malfunction. The goal is to determine which tasks will be completed and
how they will be completed
Unplanned maintenance s any maintenance task that occurs
unexpectedly. It happens when there is no formal strategy in place to
address a repair, replacement, or inspection before it's needed.
Unplanned maintenance is commonly the result of equipment failure that
was not anticipated.
Preventive maintenance (PM) is scheduled maintenance that is
performed to prevent equipment from failing. This type of maintenance is
typically performed on a regular basis, such as monthly or annually. PM
can help to extend the life of equipment and reduce the risk of unplanned
downtime.
Corrective maintenance (CM) is performed to repair or replace
equipment that has already failed. This type of maintenance is typically
unplanned and can be costly. CM can help to restore equipment to its
normal operating condition, but it does not address the root cause of the
failure.
Advantages of Preventive Maintenance :
i. Reduces failures and downtime. That is, it increases the
availability of equipment and facilities.
ii. Improves the use of resources
iii. Action is taken on the origin of the fault.
iv. It allows the company to have a history of all the equipment, also
provides the possibility of updating the technical information of the
equipment.
v. Reduce inventory levels.
vi. It allows having a budget approved by the board of directors.
vii. Improves the life of equipment and facilities.
Disadvantages of Preventive Maintenance :
i. Experience and technical capacity of maintenance personnel are
required as per the manufacturer’s recommendations to make the
maintenance schedule for the equipment.
ii. It does not allow to determine exactly the wear or decrease of the parts
of the equipment.
iii. The infrastructure represents a considerable initial investment.
iv. The labor used in this type of maintenance must be qualified, for hence
its cost increases.
v. Components are replaced based on the average lifetime of the ports,
wasting a useful life that can belong.
Advantages of Corrective maintenance
i. It does not require a large technical setup or high analytical capacity.
ii. Corrective maintenance maximizes the use of the equipment’s useful
life.
Disadvantages of Corrective maintenance
i. Disturbance to production takes place due to unexpected faults.
ii. Risk of failure of elements that are difficult to acquire, which implied
the need for an important spare parts stock.
iii. Low quality of maintenance as a consequence of the little time
available for repair.
Predictive maintenance (PdM) is a type of maintenance that uses data
and analytics to predict when equipment is likely to fail. This type of
maintenance can help to prevent unplanned downtime and reduce the
cost of maintenance. PdM uses sensors and other monitoring devices to
collect data about the equipment's condition. This data is then analyzed
by software to identify patterns that indicate that the equipment is likely to
fail.
Condition-based maintenance (CBM) is a type of maintenance that is
performed based on the condition of the equipment. This type of
maintenance is typically performed using sensors and other monitoring
devices to collect data about the equipment's condition. CBM can help to
prevent unplanned downtime and extend the life of equipment.
Advantages of Predictive Maintenance :
i. Reduces downtime by knowing exactly which organ is failing.
ii. It allows following the progress of a defect over time.
iii. Optimizes the management of maintenance personnel.
iv. Requires a smaller maintenance staff.
v. It allows knowing exactly the time limit for action that does not
imply the development of an unforeseen failure.
vi. It allows making decisions about stopping a line of machines in
moments of critics.
vii. Guarantees the preparation of internal form of operations or
purchases of the new team.
Disadvantages of Predictive Maintenance :
i. The implementation of such a system requires a significant initial
investment, fault detection equipment. Ex: Vibration analyzers, high
cost involved.
ii. Qualified personnel must be assigned to carry out the periodic reading
of data in the equipment to be used.
iii. It is justified in machines or installations where untimely shutdowns
cause high losses, where unnecessary downtime results in high costs.
