TYPES OF
MAINTENANCE
SYSTEMS
Submitted to: Dr. Rajani Jain
Submitted By:
Aditi Chakraborty (01)
Jatin Mandhyan (06)
Shaik Areef (18)
Shalini Yadav (19)
INDEX
[Link].
CONTENT
PAGE NO.
Introduction
Maintenance Objectives
Maintenance Philosophies
Types Of Maintenance Systems
4-5
Breakdown Maintenance (Run-ToFailure Management)
Predictive Maintenance (PDM)
Preventive Maintenance (PM)
7-9
Corrective Maintenance (CM)
9-10
Improvement Maintenance (IM)
10-11
10
Reliability
(RCM)
11-12
11
Conclusion
13
12
Bibliography
14
13
Annexure (Case Study)
Centered
2-3
Maintenance
5-7
15-22
INTRODUCTION
Maintenance encompasses all those activities that maintain facilities & equipment in
good working order so that a system can perform as intended. Maintenance can also
be termed as asset management system which keeps them in optimum operating
condition.
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. Activities of
maintenance function could be either repair or replacement activities, which are
necessary for an item to reach its acceptable productivity condition or these
activities, should be carried out with a minimum possible cost.
The general opinion has been maintenance is a necessary evil or nothing can
be done to improve maintenance costs. Perhaps these were true statements 10
or 20 years ago. However, the developments of microprocessor or computer-based
instrumentation that can be used to monitor the operating condition of plant
equipment, machinery, and systems have provided the means to manage the
maintenance operation. They have provided the means to reduce or eliminate
unnecessary repairs, prevent catastrophic machine failures, and reduce the negative
impact of the maintenance operation on the profitability of manufacturing and
production plants.
MAINTENANCE OBJECTIVES
Maintenance objectives should be consistent with and subordinate to production
goals. The relation between maintenance objectives and production goals is
reflected in the action of keeping production machines and facilities in the best
possible condition.
Maximising production or increasing facilities availability at the lowest cost
and at the highest quality and safety standards.
Reducing breakdowns and emergency shutdowns.
Optimising resources utilisation.
Reducing downtime.
Improving spares stock control.
Minimising energy usage.
Optimising the useful life of equipment.
Providing reliable cost and budgetary control.
Identifying and implementing cost reductions.
Improving equipment efficiency and reducing scrap rate.
Figure 1: Maintenance Objectives
MAINTENANCE PHILOSOPHIES
Industrial and process plants typically utilize two types of maintenance management:
(1) Run-to-failure(Breakdown Maintenance)
(2) Preventive maintenance.
Figure 2: Types of Maintenance Systems
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BREAKDOWN MAINTENANCE (RUN-TO-FAILURE MANAGEMENT)
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.
Reactive maintenance (repair) : referred to break down, repair, fix-when-fail, or
run-to-fail (RTF) maintenance , trouble calls are typical type of reactive maintenance
, when applying this technique, maintenance, components repair, or replacement
happens only when failure takes place in the component's functional tree, this
technique assumes failure is equally likely to happen in any system, component or
device, and failure is age related, this leads to identify a specific group of repair
parts, as being more necessary or desirable that others.
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.
The logic of run-to-failure management is simple and straightforward. When a
machine breaks, fix it. This if it isnt broke, dont fix it method of maintaining plant
machinery has been a major part of plant maintenance operations since the first
manufacturing plant was built, and on the surface sounds reasonable. A plant using
run-to-failure management does not spend any money on maintenance until a
machine or system fails to operate. Run-to-failure is a reactive management
technique that waits for machine or equipment failure before any maintenance
action is taken. It is in truth a no-maintenance approach of management. It is also
the most expensive method of maintenance management. Few plants use a true
run-to-failure management philosophy. In almost all instances, plants perform basic
preventive tasks (i.e., lubrication, machine adjustments, and other adjustments) even
in a run-to-failure environment. However, in this type of management, machines and
other plant equipment are not rebuilt nor are any major repairs made until the
equipment fails to operate.
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.
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.
The major expenses associated with this type of maintenance management
are:
(1) High spare parts inventory cost,
(2) High overtime labor costs,
(3) High machine downtime,
(4) Low production availability.
Since there is no attempt to anticipate maintenance requirements, a plant that uses
true run-to-failure management must be able to react to all possible failures within
the plant. This reactive method of management forces the maintenance department
to maintain extensive spare parts inventories that include spare machines or at least
all major components for all critical equipment in the plant. The alternative is to rely
on equipment vendors that can provide immediate delivery of all required spare
parts. Even if the latter is possible, premiums for expedited delivery substantially
increase the costs to Maintenance Fundamentals of repair parts and downtime
required for correcting machine failures.
To minimize the impact on production created by unexpected machine failures,
maintenance personnel must also be able to react immediately to all machine
failures. The net result of this reactive type of maintenance management is higher
maintenance cost and lower availability of process machinery. Analysis of
maintenance costs indicates that a repair performed in the reactive or run-to-failure
mode will average about three times higher than the same repair made within a
scheduled or preventive mode. Scheduling the repair provides the ability to minimize
the repair time and associated labor costs.
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
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.
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. 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
Like preventive maintenance, predictive maintenance has many definitions. To
some, predictive maintenance is monitoring the vibration of rotating machinery in an
attempt to detect incipient problems and to prevent catastrophic failure. To others, it
is monitoring the infrared image of electrical switchgears, motors, and other electrical
equipment to detect developing problems.
The common premise of predictive maintenance is that regular monitoring of the
mechanical condition of machine-trains will ensure the maximum interval between
repairs and minimize the number and cost of unscheduled outages created by
machine-train failures. Predictive maintenance is much more. It is the means of
improving productivity, product quality, and overall effectiveness of our
manufacturing and production plants.
Predictive maintenance is not vibration monitoring or thermal imaging or lubricating
oil analysis or any of the other non-destructive testing techniques that are being
marketed as predictive maintenance tools. Predictive maintenance is a philosophy or
attitude that, simply stated, uses the actual operating condition of plant equipment
and systems to optimize total plant operation.
There are five non-destructive techniques normally used for predictive
maintenance management:
(1) Vibration monitoring,
(2) Process parameter monitoring,
(3) Thermography,
(4) Tribology, and
(5) Visual inspection.
Each technique has a unique data set that will assist the maintenance manager in
determining the actual need for maintenance. How do you determine which
technique or techniques are required in your plant? How do you determine the best
method to implement each of the technologies?
If you listen to the salesman for the vendors that supply predictive maintenance
systems, his is the only solution to your problem. How do you separate the good
from the bad? Most comprehensive predictive maintenance programs will use
vibration analysis as the primary tool.
Since the majority of normal plant equipment is mechanical, vibration monitoring will
provide the best tool for routine monitoring and identification of incipient problems.
However, vibration analysis will not provide the data required on electrical
equipment, areas of heat loss, condition of lubricating oil, or other parameters that
should be included in your program.
Figure 4: Structure of Maintenance.
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. 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.
The advantage of applying preventive maintenance activities is to satisfy most of
maintenance objectives.
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.
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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.
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.
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.
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.
There are many definitions of preventive maintenance, but all preventive
maintenance management programs are time driven. In other words, maintenance
tasks are based on elapsed time or hours of operation. Figure 5 - illustrates an
example of the statistical life of a machine-train.
Figure 5 The Bathtub Curve
8
The mean time to failure (MTTF) or bathtub curve indicates that a new machine has
a high probability of failure, because of installation problems, during the first few
weeks of operation. After this initial period, the probability of failure is relatively low
for an extended period of time. Following this normal machine life period, the
probability of failure increases sharply with elapsed time.
In preventive maintenance management, machine repairs or rebuilds are scheduled
on the basis of the MTTF statistic. The actual implementation of preventive
maintenance varies greatly. Some programs are extremely limited and consist of
lubrication and minor adjustments. More comprehensive preventive maintenance
programs schedule repairs, lubrication, adjustments, and machine rebuilds for all
critical machinery in the plant. The common denominator for all of these preventive
maintenance programs is the scheduling guideline. All preventive maintenance
management programs assume that machines will degrade within a time frame
typical of its particular classification. Analysis of maintenance costs has shown that
a repair made in a reactive mode (i.e., after failure) will normally be three times
greater than the same repair made on a scheduled basis.
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. The maintenance carried out after recognition and
intended to put an item into a state in which it can perform a required function.
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.
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.
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
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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 plants
machines and equipment in optimum operating condition.
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 has several prerequisites in order to be carried out
effectively:
[Link] identification of incipient problems.
[Link] 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.
[Link] repair procedures.
[Link] time to repair.
[Link] of repair.
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.
2. Engineering services which includes construction and construction modification,
removal and installation, and rearrangement of facilities.
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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.
RELIABILITY CENTRED MAINTENANCE (RCM):
Reliability centred maintenance (RCM): Integrates preventive maintenance (PM) with
predictive testing and inspection and repair (known as reactive maintenance), with
also proactive maintenance to increase the probability for a machine to function in
the designed way , so it can reaches its designed life cycle with the minimum
maintenance costs, and minimum downtime, RCM integrates these strategies and
principles to gather so they are optimally integrated, so all strategies advantages can
be achieved, so resulting by maximizing reliability of systems and components while
minimizing maintenance cost and downtime.
RCM objectives:
1- Insure realization of the inherent safety and reliability levels of the
system/components.
2- Restore the system/components to these inherent levels when deterioration
occurs.
3- To obtain the information and data necessary for design the improvement and
adjustments of these items where their inherent reliability start to be inadequate.
4- To achieve these goals at minimum total cost, including maintenance cost,
support costs, and economic consequences of operational failure.
RCM Strategies
1- Reactive (repair) maintenance, run to fail maintenance (RTF).
2- Preventive maintenance (PM), time based maintenance.
3- Predictive testing and inspection (PT&I), condition based maintenance.
4- Proactive maintenance.
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PROACTIVE MAINTENANCE (ROOT CAUSE MAINTENANCE)
Proactive Maintenance (root cause maintenance): Improves maintenance through
better design installation, maintenance activities, work men ship and scheduling.
Characteristics of proactive maintenance:
1) Using feedback and communications to ensure that changes in design or
procedures are rapidly made available to designers and managers.
2) Employing a life cycle view of maintenance and supporting functions.
3) Ensuring that nothing affecting maintenance and it is occurs in isolation.
4) Employing continuous process of improvement.
5) Optimizing and tailoring maintenance techniques and technologies to each
application.
6) Integrating functions that support maintenance into program planning.
7) Using root cause failure and predictive analysis to maximize maintenance
effectiveness.
8) Adopting an ultimate goal of fixing components permanently.
9) Periodic evaluation of technical content and performance intervals of
maintenance tasks.
Essential techniques to extend the component life or reach its designed life:
1- Specifications of new/rebuilt components.
2- Commissioning.
3- Precision rebuild and installation.
4- Failed components analysis.
5- Root cause failure analysis.
6- Reliability engineering.
7- Rebuilt certification/verification.
8- Age Exploration and the relationship with replacement of obsolete items.
9- Recurrence control.
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CONCLUSION (MANAGEMENT OF MAINTENANCE)
There is a lot of work required to set up a successful maintenance management
system. However, once it is in place, most of the data and calculations remain the
same from year to year. Changes are required only when there is an addition or
deletion to the inventory or when cost increases and estimates need to be corrected.
In these cases, the appropriate work orders and schedule must be revised and the
labour, equipment, material and contract costs updated for the New Year. There are
numerous computerized maintenance management systems available in the
commercial market to assist in effectively managing the maintenance of on reserve
assets. The maintenance supervisor or manager must also monitor the work
progress daily, weekly or monthly depending on the nature of the situation and the
potential impact of a service breakdown to the community. He or she must not wait
until the year end to review the budget, as it would be too late to take any corrective
action if it were necessary. Any significant variance in labour hours, work order costs
or total maintenance cost for a particular asset should be identified through
exception reporting. The supervisor should determine the cause of the variance and,
where possible, develop alternative solutions or actions to reduce time and costs.
Taking these steps will help improve the efficiency and effectiveness of the
maintenance program.
Total maintenance cost comprises of both breakdown maintenance cost and
planned maintenance cost so there should be proper harmony between both
the value, neither less maintenance nor too much maintenance and get the
cost minimum.
Preventive cost of maintenance is less then Breakdown maintenance cost. So
regularly planned maintenance should be done.
No company can follows a single type of maintenance system, every
company uses mix of maintenance system types according to the
companys needs.
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BIBLIOGRAPHY
REFRENCE DOCUMENTS:
Maintainance Engineering and Management - R.C. Mishra and [Link].
(Chapter 1).
Case Study Types of Maintenance Systems.
REFERNCE LINKS
[Link]
[Link]
[Link]
[Link]
[Link]
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