Condition Monitoring and Maintenance (MT-362)

MAINTENANCE
BY
ENGR.UMER FAROOQ
LAB ENGINEER GSPCT GUJRAT
L-02
Process Industry

 When a manufacturing company begins production of a new material, it has a

choice as to the manufacturing process it uses. The type of process depends on the
facility, the staff, and the information systems available. Each process has its
advantages and some are best at certain tasks, for example, large batches of
finished goods, or small numbers of custom items.
Process Industry

 When the decision is being considered about which manufacturing process to use,
there are a number of questions that should be asked;
 what are the volumes to be produced?
 what are the requirements to make the product?
 Does the company manufacture a similar product?
Basic manufacturing processes

 There are a number of basic manufacturing processes that they can select from;
 Production line.
 Continuous flow.
 Custom manufacturing
and
 Fixed position manufacturing.
 CONDITION
MONITORING &
MAINTENANCE
L-02
MAINTENANCE DEFINITION

THE COMBINATION OF ALL TECHNICAL AND

ADMINISTRATIVE ACTIONS, INCLUDING
SUPERVISION ACTIONS, INTENDED TO RETAIN AN
ITEM IN, OR RESTORE IT TO, A STATE IN WHICH IT
CAN PERFORM A REQUIRED FUNCTION.
MAINTENANCE DEFINITION

MAINTENANCE IS A SET OF ORGANISED ACTIVITIES THAT

ARE CARRIED OUT IN ORDER TO KEEP AN ITEM IN ITS
BEST OPERATIONAL CONDITION WITH MINIMUM COST
ACQUIRED.
MAINTENANCE HISTORY

-Term terotechnology
introduced.
-Recognition of need to
present equipment
Development of
Maintenance

failures.
-Models for preventive
maintenance
developed. -Increased awareness
of:
-Environment
Fix the equipment -Safety
when it breaks -Quality
-Need for reliable
equipment.
-Reduction in costs.

Pre-World War II Post-World War II 1980 Onwards

Figure 2.2 Maintenance History

(Adapted From Shenoy, Bhadury 1998)
MAINTENANCE OBJECTIVES
DESIGN AND MAINTENANCE

MAINTENANCE AND RELIABILITY

MAINTENANCE AND PRODUCT QUALITY

MAINTENANCE AND PRODUCTIVITY

MAINTENANCE AND SAFETY

MAINTENANCE AND SUPPLY CHAIN, JIT

FAILURE CAUSE DISRUPTION, WASTE,

ACCIDENT, INCONVENIENCE AND
EXPENSIVE
MAINTENANCE OBJECTIVES
PLANT

Maximising Production Reduce Breakdowns

M
A
Minimising Energy I Reduce Downtime
Usage N
T
Optimising Useful Life of Improving Equipment
E
Equipment Efficiency
N
Providing Budgetary A Improving Inventory
Control N Control
C
Optimising Resources E Implementing Cost
Utilisation Reduction
TYPES OF MAINTENANCE
 RUN TO FAILURE MAINTENANCE (RTF)

 CORRECTIVE MAINTENANCE (CM)

 PREVENTIVE MAINTENANCE (PM)

 IMPROVEMENT MAINTENANCE (IM)

 PREDICTIVE MAINTENANCE (PDM)

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
INTRODUCTION TO
TYPES OF
MAINTENANCE
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.

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.
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.
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.
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 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.
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.
CORRECTIVE MAINTENANCE (CM)

 DEFERRED MAINTENANCE:

 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:

 A SET OF CORRECTIVE MAINTENANCE

ACTIVITIES THAT ARE PERFORMED WHEN THE
PRODUCTION LINE IS IN TOTAL STOPPAGE
SITUATION.
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, &

 THE REDUCTION OF THE DEVIATIONS FROM

OPTIMUM OPERATING CONDITIONS.
CORRECTIVE MAINTENANCE (CM)
 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 (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.
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.
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.
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.
PREVENTIVE MAINTENANCE (PM)

 THE ADVANTAGE OF APPLYING

PREVENTIVE MAINTENANCE ACTIVITIES IS
TO SATISFY MOST OF MAINTENANCE
OBJECTIVES AS DESCRIBED EARLIER
SUCH AS MAXIMIZING PRODUCTION,
OPTIMIZING THE RESOURCES, REDUCE
BREAKDOWNS, AND REDUCE DOWNTIME
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.
PREVENTIVE MAINTENANCE (PM)

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.
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.
PREVENTIVE MAINTENANCE (PM)
 THE FACTORS THAT AFFECT THE EFFICIENCY
OF THIS TYPE OF MAINTENANCE:

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.
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.
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.
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.
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.
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.
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
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.
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.
PREDICTIVE MAINTENANCE (PDM)

 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.