Unit 1 - 15 Marks, Easy

DIFFERENT TYPES OF MAINTENANCE SYSTEM IN DETAIL
Classification of Maintenance Approach:
Basically there are two types of maintenance tasks. They are

I. Break Down Maintenance
II. Planned Maintenance
Planned maintenance may further be classified into
A) Preventive Maintenance
B) Corrective Maintenance
C) Predictive Maintenance
D) Condition Based Maintenance
E) Reliability Centered Maintenance
BREAK DOWN MAINTENANCE OR REACTIVE MAINTENANCE:

In this category, less attention is given to the operating condition of critical machinery, equipment or
system. Here the equipment is allowed to function till no failure occurs no long as the equipment is
functioning at a minimum acceptable level, it is assumed to be effective. This means
the people wait till the equipment fails and repair. This approach of maintenance is ineffective and
extremely expensive. The following factors contribute to high maintenance costs.
i) Poor planning
ii) Incomplete repair
Limitations:
a) Most repairs are poorly planned due to time constraint caused by production
and plant management. This will cost three to four times than the same repair when it is well planned.
b) This approach focus only on repair or the symptoms of failure and not on the
root cause of failure. This results only in increase in the frequency of repair
and correspondingly the maintenance costs.
PREVENTIVE MAINTENANCE:
It is a maintenance program which is committed to the elimination or prevention of corrective and
breakdown maintenance. A comprehensive preventive maintenance program involves periodical
evaluation of critical equipment, machinery to detect problem and schedule maintenance task to avoid
degradation in operating conditions.
Benefits of Preventive Maintenance:
In general the cost incurred towards breakdown maintenance is usually higher than the cost incurred on
preventive maintenance. It maintains the equipment in good condition to preventing them from bigger
problems. Prolongs the effective life of the equipments. Detects the problem at earlier stages.
Minimizes / eliminates the rewash/ scrap and help in reducing the process variability. Significantly
reduces unplanned downtime.
CORRECTIVE MAINTENANCE:
Corrective Maintenance is the program focused on regular planned tasks that will maintain all critical
machinery and system in optimum operating conditions. The effectiveness of this program is judged on
the cycle cost of critical equipment rather than on how quickly the broken machines are restored to
working conditions. It is proactive approach towards maintenance management.
The main objectives of this program are to
i) Eliminate breakdowns
ii) Eliminate deviations from optimum operating conditions.
iii) Eliminate unnecessary repairs.
iv) Optimize all critical plant systems.
As per this program, all the repairs are well planned and implemented by properly trained people and
the equipment or system is verified and returned to service.
PREDICTIVE MAINTENANCE:
Predictive maintenance is a management technique that uses regular evaluation of the actual
operating conditions of plant equipment, production systems and plant management functions to
optimize total plant operation. It is not a solution for all the factors that limit total
plantperformance.
CONDITION BASED MAINTENANCE:
The various techniques are
Vibration Monitoring –determines the actual condition of equipments / machines by studying
the noise or vibration produced during functioning.
Thermography –determines the condition of plant machinery systems etc by studying the
emission of infra red energy ie temperature.
Tribology –determines the dynamic condition of bearing lubrication, rotor support structure of
machinery etc by adopting any one of the techniques like lubricating oil analysis, spectrographic
analysis, ferrography and wear particle analysis.
Electrical Motor Analysis –determines the problem within motors and other electrical
equipments.
Visual inspection -determines the conditions of working elements visually based
on the experience.
REALIBILITY CENTERED MAINTENANCE (RCM)
It is one of the well-established systematic and a step by step
instructional tool for selecting applicable and appropriate maintenance
operation types. It helps in hw to analyze all failure modes in a system
and define how to prevent or find those failures early. The rough process
of a CM is as follows.
Target products or systems of maintenance should be clearly identified,
and necessary data should be collected.
All possible failures and their effect on target produced or systems are
systematically analyzed.
Preventive or corrective maintenance operations are considered selection of operations is
done based on rational calculation of effectiveness of such operations for achieving required
maintenance quality, such as reliability, cost etc.
Applications of RCM:
When designing, selecting and installing new systems in a plant.
When setting up preventive maintenance for complex equipment and systems for
which we are not clear on how they work.
When teaching people the basics of reliability it helps to explain the matters in a
detailed fashion using RCM.

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DIFFERENT TYPES OF MAINTENANCE SYSTEM IN DETAIL

Classification of Maintenance Approach:

Basically there are two types of maintenance tasks. They are

BREAK DOWN MAINTENANCE OR REACTIVE MAINTENANCE:

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