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Maintenance Types

The document discusses different types of maintenance strategies including planned and unplanned maintenance. Planned maintenance includes periodic, condition-based, preventative, and predictive maintenance which aim to prevent failures. Unplanned or corrective maintenance involves fixing equipment after it breaks down. Periodic maintenance involves regular inspections and repairs. Condition-based maintenance monitors indicators to service equipment before failure. Preventative maintenance replaces parts at fixed intervals to extend equipment life. Predictive maintenance uses tools like vibration analysis to detect degradation early.

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53 views

Maintenance Types

The document discusses different types of maintenance strategies including planned and unplanned maintenance. Planned maintenance includes periodic, condition-based, preventative, and predictive maintenance which aim to prevent failures. Unplanned or corrective maintenance involves fixing equipment after it breaks down. Periodic maintenance involves regular inspections and repairs. Condition-based maintenance monitors indicators to service equipment before failure. Preventative maintenance replaces parts at fixed intervals to extend equipment life. Predictive maintenance uses tools like vibration analysis to detect degradation early.

Uploaded by

Kopi143
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PDF, TXT or read online on Scribd
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Maintenance

Eng.: Mohamed Khaled El-Sayed


[email protected]

Contents:
1- Introduction. 2- General Types Of Maintenance:
2-1- Unplanned Maintenance. 2-2- Planned Maintenance. - Periodic maintenance. - Maintenance, Repair & Operations. - Condition-based Maintenance. - Preventive Maintenance. - Predictive Maintenance. - Corrective Maintenance.

Introduction:
The dictionary defines maintenance as follows: The work of keeping something in proper condition; upkeep. This would imply that:

Maintenance should be actions taken to prevent a device or component from failing or to repair normal equipment degradation experienced with the operation of the device to keep it in proper working order.

Benefit Of Maintenance:
1. Maintain the quality of the product.

2. Increase production up-time.


3. Reduce costs of operations. 4. Reduce amount and complexity of machinery required. 5. Increase equipment capability.

General Types Of Maintenance:


1- Unplanned or Reactive (Breakdown) Maintenance. 2- Planned Maintenance.
2-1- Periodic maintenance ( Time based maintenance - TBM) 2-2- Maintenance, Repair & Operations. 2-3- Condition-based Maintenance. 2-4- Preventive Maintenance. 2-5- Predictive Maintenance. 2-6- Corrective Maintenance.

1- Reactive Maintenance:
Reactive maintenance is basically the Run it, till it breaks or Run to fail maintenance mode. No actions or efforts are taken to maintain the equipment as the designer originally intended to ensure design life is reached. All maintenance work unplanned.
Example: Light bulb replacement.

1- Reactive Maintenance:
Advantages
Low cost maintenance. Less staff.

Disadvantages
Increased cost due to unplanned downtime of equipment. Increased labor cost, especially if overtime is needed. Cost involved with repair or replacement of equipment. Possible secondary equipment or process damage from equipment failure. Inefficient use of staff resources.

Breakdown Causes:
1.Basic conditions neglected.

2.Inadequate skills.
3.Operating standard not followed. 4.Deterioration unchecked.

5.Inherent design weakness.

2- Planned Maintenance:
The goal of planned maintenance is to achieve the absolute minimum amount of needs for effective maintenance.

Planed Maintenance Technique: Definition:


It is a system of activities in which all staff work to improve up-time, quality of output and reduce maintenance cost through the continuous improvement of equipment operation. Including preventive and predictive scheduled maintenance programs.

2-1-Periodic maintenance:
Periodic maintenance or time based maintenance consists of: Periodically 1- Inspecting. 2- Servicing and cleaning equipment. 3- Replacing parts. To prevent sudden failure and process problems.

2-1-Periodic maintenance:
Periodic maintenance is defined as: Significant activities carried out regularly (according to predetermined schedule) to maintain the condition or operational status of a building, equipment, machine, plant or system.

This can be done daily, weekly, monthly, every 60 days, quarter yearly, semiyearly and yearly.

2-2- Maintenance, Repair & Operations:

Maintenance, repair, and operations (MRO) involves fixing any sort of mechanical or electrical devices should it become out of order or broken. MRO is Known as repair, unscheduled or casualty maintenance).

2-2- Maintenance, Repair & Operations: MRO may be defined as: "All actions which have the objective of retaining or restoring an item in or to a state in which it can perform its required function. The actions include the combination of all technical and corresponding administrative, managerial, and supervision actions.

2-3-Condition based maintenance:


Condition based maintenance is described as The maintenance when need arises. This maintenance is performed after some of indicators shows that equipment is going to fail or that equipment performance is deteriorating. Condition-based maintenance (CBM) is introduced to try to maintain the correct equipment at the right time.

2-3-Condition based maintenance: CBM advantages:


Improved system reliability. Decreased maintenance costs. Decreased number of maintenance operations causes decreasing of human error influence.

2-3-Condition based maintenance:


CBM disadvantages are:
High installation costs, for minor equipment items more than value of equipment. Unpredictable maintenance periods are causing costs to be divided unequally. Increased number of parts (CBM installation) that need maintenance and checking.

2-4- Preventative Maintenance:


Preventative maintenance is: Maintenance which is carried out to prevent an item failing or wearing out by providing systematic inspection, detection and prevention of incipient failure.
Example: Changing oil & filters.

2-4- Preventative Maintenance:


Preventive Maintenance is an equipment maintenance strategy based on replacing, overhauling or remanufacturing an item at a fixed interval, regardless of its condition at the time. It has a periodic actions as:
Periodic adjustments & checks. Periodic replacement of worn parts. Periodic overhauls.

2-4- Preventative Maintenance:


Preventative maintenance program will be used to manage scheduled maintenance performed at specific intervals to sustain the functional and operational capabilities of equipment or systems. The preventative maintenance efforts are aimed at preserving the useful life of equipment and avoiding premature equipment failures, minimising any impact on operational requirements.

2-4- Preventative Maintenance:


In addition to the routine aspects of cleaning, adjusting, lubricating and testing, we have to perform inspections to identify impending problems and schedule repairs prior to equipment failure and/or further degradation. Preventative maintenance is carried out only on those items where a failure would have expensive or unacceptable consequences. Examples: Lifts, fire alarms, electricity supply and gas supply.

2-4- Preventative Maintenance:


Advantages:
1. Cost effective in many capital intensive processes. 2. Flexibility allows for the adjustment of maintenance 3. periodicity. 4. Increased component life cycle. 5. Energy savings. 6. Reduced equipment or process failure.

2-4- Preventative Maintenance:


Disadvantages:
1. Catastrophic failures still likely to occur. 2. Labor intensive. 3. Includes performance of unneeded maintenance. 4. Potential for incidental damage to components in conducting unneeded maintenance.

2-5- Predictive Maintenance:


It is defined as: Measurements that detect the onset of a degradation mechanism, thereby allowing casual stresses to be eliminated or controlled prior to any significant deterioration in the component physical state.
Examples: Vibration analysis, Noise Analysis and Infrared temperature analysis.

2-5- Predictive Maintenance:


Advantages
1. Increased component operational life/availability. 2. Allows for preemptive corrective actions. 3. Decrease in equipment or process downtime. 4. Decrease in costs for parts and labor. 5. Better product quality. 6. Improved worker and environmental safety. 7. Improved worker moral. 8. Energy savings.

2-5- Predictive Maintenance:


Disadvantages
1. Increased investment in diagnostic equipment. 2. Increased investment in staff training. 3. Savings potential not readily seen by management.

2-6- 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 the most commonly used maintenance approach, but it is easy to see its limitations.

2-6- Corrective maintenance:


When equipment fails, it often leads to downtime in production, and sometime it causes spreading of damage to other parts. In most cases this is costly business. Also, if the equipment needs to be replaced, the cost of replacing it alone can be substantial. Reliability of systems maintained by this type of maintenance is not known and can not be measured.

2-6- Corrective maintenance:

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.

Comments and Questions

Thank you for Attention


Please write your comments & feedback to [email protected]

Mohamed Khaled El-Sayed

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