MAINTENANCE

Tasks performed to ensure that a team performs

that which, whoever uses it, wants it to do.
This is the basic definition of maintenance and has endured through the
time, what has been changing are the methods of planning, execution and
control that has been adapted to the technological progress of machines.
The maintenance of a space station corresponds to the previous definition,
what the caveman did to sharpen the stone to be more effective
in the fight with the beast, it also responded.
This Module will discuss the types of maintenance that are practically
ruled production and services until almost the end of the 20th century and that
are found in use in many current organizations, especially the
mediums and small ones. In the next Module, it will be seen how they varied.
criteria with changes in technology.
It will clarify the concept of maintenance more. Of every machine that
develop a product or a service (e.g. button-making machine, a lathe,
a truck) is expected to always function, and that is how many times it
they make economic efforts when acquiring it with the satisfaction of having
It is a good investment because the mentioned machine "is expensive but does not fail."
However, no matter how perfect its design and technology are
construction, the elements that compose it -mechanisms, circuits-
they will be subject to wear and tear, potentially failing or suffering damage, depending on that
of many variables, some of which are random. All of this makes that
the produced product or the provided service decreases in quality.
To ensure that a team fulfills the specific function or functions
desired, that is, to maintain oneself one should do tasks such that:
. Regarding wear: make it happen as much as possible
as slowly as possible and once they arrive at
a certain magnitude, to return these to dimensions that
ensure that the performance remains within the values
of design.
. Regarding failures and defects: predict them, prevent them, look for them,
find them, correct them.
Essence two tasks constitute the
maintenance.
From the above, it would seem that maintenance tasks are to be done.
exclusively on machines, however, if one analyzes what was written before, one
is that it applies to all engineering products, whether static or
dynamic, example:
. Painting a house.
. Sharpen a knife.
It turns out that maintenance is universally applicable and is
becomes essential when such engineering products are used
to produce or provide a service, since without it increases the
probability of cessation of function, which in turn results in cessation of
production or provision.
Definition of new concepts used.

WEAR
Change in the geometry of a part due to loss of
material and/or variation of the shape.
FAILURE
It is a technical event that causes a team to stop
fulfill its function.
DEFECT
It is a technical event that, while it does not cause a team
it stopped working, if not repaired in time
peremptory, it will turn into a failure.

Control variable
CONTROL VARIABLE
The Control Variable measures the lifespan of the UNITS
the TEAMS and allows establishing the periods of
maintenance.
Depending on the type of equipment, it can be:
. Calendar time.
. Flight hours.
. Kilometers traveled.
. Nautical miles.
. Operating hours
. Kilowatts produced.

The CONTROL VARIABLE measures how time passes for the UNIT
oEQUIPO, in other words how their life unfolds, the ones that can be
two and are applicable in maintenance management:

. Technical life.
. Economic life.

TECHNICAL LIFE
Time elapsed since a UNIT or
TEAM begins to fulfill its function until
that a natural degradation occurs of the
performance and stop fulfilling it.
Through a maintenance action, functional capacity is restored.
When another technical life is completed, work will resume on the equipment.
to restore it and thus the technical lives will follow.

PERFORMANCE
Operating characteristic of a UNIT or
TEAM that defines its capacity to fulfill
a function.

Economic Life
It is the one that takes place from the appearance of a
UNIT or TEAM in the market, until it is
displaced by another more effective and efficient, that is
until it becomes obsolete.

Qualities conferred by maintenance

Through maintenance, it is intended to confer the following to the equipment
qualities that ensure the quality of production or service operations
to those who are destined:
RELIABILITY
It is the quality of a unit or team by which
fulfills its production or service function without
suffer failures, being obtained through a
adequate operation and maintenance.
SECURITY
It is the quality of a unit or team by which
fulfills its production or service function without
causing damage to people and/or things even in the event
of failure, and is obtained through a correct
design and proper maintenance.
AVAILABILITY
It is the quality of a team, by which it fulfills
its production or service function with
reliability and security, in the opportunity in
that was scheduled for it. It is obtained with
proper maintenance and an effective
planning of it.

Types of maintenance
The types of maintenance that we will discuss below are:
Preventive Maintenance
Predictive Maintenance
Corrective Maintenance

The classical definitions of these types are given below.

maintenance in order to continue with this first module.
This topic will be further elaborated on later.

PREVENTIVE MAINTENANCE
It is the sum of tasks that are carried out on a
machine according to a frequency
determined in order to reduce, to the least
possible cost, the probability of failure of the
same. These tasks are carried out even though the
the machine does not fail and is generally necessary
take it out of service to make them.
PREDICTIVE MAINTENANCE
It consists of carrying out on a machine
measurements periodicals of variables
previously chosen y, by means of
systematic comparisons, establish the
the need -or not- to carry out work
maintenance. There is no need to take out the
service machine.
Corrective Maintenance
It is the sum of tasks that are carried out on a
machine that has suffered a failure, with the
purpose of restoring its capacity to
fulfill its function. It is always necessary to take out
the service machine.

Predictive and preventive maintenance are carried out according to a

programming is taking place even if failures have not occurred. The
Corrective action is taken when the failure or defect has appeared. The first two...
one is scheduled, the other is not, so they can also be grouped as:

SCHEDULED MAINTENANCE
Group the PREVENTIVE and PREDICTIVE, they are
carried out according to a regularity
established earlier, and carried out there
Oh, it doesn't fail. The periodicity is measured by the
CONTROL VARIABLE.
UNSCHEDULED MAINTENANCE
It is the CORRECTIVE and is carried out to solve
a fault. It is carried out upon its appearance and not
respond to a schedule.

Preventive maintenance.

Preventive maintenance had been defined as the sum of tasks

that are performed on a machine according to a frequency
determined in order to reduce, at the lowest possible cost, the probability
in case of its failure. These tasks are performed even if the machine does not fail and
It is generally necessary to take it out of service to do them.
Preventive maintenance arises from the following concept: in
identical machines, in equal times, experience wear and failures
equal. With this premise and abundant information on real failures,
develop a probabilistic model that allows to apply philosophy
tacitly expressed in the definition: prevent failure by intervening at
time.

This type of maintenance is characterized by the replacement of parts and/or

prescribed tasks, with the purpose of:
. Replacement of parts: those that have reached are replaced.
a stage of life when failure is imminent, examples:
1. The oil that has reached a certain number of hours or
kilometers degrading its lubricating quality.
2. The air filter, also with a certain number of hours or
kilometers, which accumulated such a number of particles that it causes the
loss of its filtering capacity.
. Prescribed tasks: they are carried out with a predefined frequency
to slow down wear and prevent failures, examples:
Tighten loose things.
2. Fine-tune the performance.
3. Clean.
4. Lubricate.
5. Look for defects; cracked belts, misaligned pulleys,
losses in pipes.

All of this is done through two types of tasks:

. General inspection
. Inspection

General route
It is a large-scale job, requiring a greater amount of hours of
work that an INSPECTION and basically consists of:
. Complete disarmament.
. Cleaning.
. Inspection.
. Repair or replacement of parts.
. Armed.
. Testing and determination of performance.
With this, the machine begins its Technical Life again. This type of
work should be applied, logically, in proximity to strong age
increase in the probability of failure corresponding to a certain value
from the Control Variable, which can be varied according to the
experience.
Inspection
It is one of the jobs where parts are replaced or tasks are performed.
prescriptions that are carried out at equal time intervals. Once carried out a
INSPECTION, the following usually contains the tasks of the first and
a few more. In turn, the following one will contain the tasks of the one carried out
previously adding others, and so on until reaching the most complex and to
from the following one begins again from the first repeating the
cycle.
The preventive Inspection Program must be carried out
regardless of the General Tour, that is, they must be carried out
two tasks.
General comments on preventive maintenance.

. It is executed through actions on the EQUIPMENT, replacement

of prescribed pieces and/or tasks, which change – improving it
the operational condition of it.
. It is the oldest philosophy of maintenance and is carried out
in search of reliability.
. Significantly reduced maintenance costs with
relationship that occurs only when a failure occurs, is
to say the pure corrective.
. In general, planning is done, especially for the Inspections, of
according to the recommendations of the Equipment factory.
. Many times hay planning excessively
conservative what is not supported by facts.
. Also, many times machines are opened during the inspection.
general, who have no problem at all.
. Other times a machine worked well, it opened, there was
human error, and after it was closed it start working
bad.
. Although it is more economical than pure corrective,
situations like the three mentioned above make it
more expensive than it should be.
Predictive maintenance.
Predictive maintenance had been defined as the task of
carry out periodic measurements of previously selected variables and,
through systematic comparisons, establish the need - or not -
to carry out maintenance work.
There are teams where there is very little or no relationship.
between the team life and the probability of failure, but many of them
and gives a kind of notice that the failure process has started to
occur. If this evidence can be found, it is feasible to take a
action to prevent failure and avoid the consequences, and thus the
predictive maintenance, which is nothing other than knowing the state of
the machines based on the symptoms of the same, that is, without
need to open them. To do this, one observes or measures periodically a
chosen variable, and the evolution of some symptom or symptoms is studied
linked to a mechanical failure of some component of the equipment,
it is necessary to know the relationship between the level of the symptom and the
worsening of the failure, which allows predicting when it is approaching the
moment of the failure.
The mentioned symptoms can be:

. Hot spots with color change in electrical insulation.

. Vibrations in a bearing.
. Cracks in a metal.
. Metallic particles in lubricant oil.
. Increase in consumption in an engine.
. Tread wear of a tire.
Just like preventive maintenance, it is carried out according to a
programming that is controlled by the CONTROL VARIABLE,
carried out even if failures have not occurred. Its characteristics
main are:
. While it is being carried out, the machine can continue to operate.
. Tasks
are not performed, but the measurement of the variable/s that
must be analyzed.
. The time between measurements is usually advised by the
factory establishing itself according to the following criteria: let us suppose
an irregularity appears in the machine from which
the fault begins to take shape, which will take time to become effective.
time t; the time between predictive measurements must be less than t.

Predictive inspection techniques.

There are many types of inspections, most of which require the use
of equipment and special instruments, and through them
they seek certain effects with which the potential failure is discovered.
They are classified under the following titles:
. Dynamic effects.
. Particles.
. Chemical effects.
. Physical effects.
. Changes in temperature.
. Electrical effects.

General comments on predictive maintenance

. It is executed through measurements taken on the UNIT or EQUIPMENT.

they do not change the operational condition, but they are made to
obtain information from it.
. Itis a new philosophy of maintenance carried out in search
of reliability, being able to coexist, as it really does,
with the preventive.
. Significantly reduced costs as a result of
excessively conservative preventive maintenance.
. Like preventive inspections, planning is done for
according to the recommendations of the Equipment factory.
. If done correctly, it prevents the opening of machines that do not
they have no problem.
. A classicexample of this type of maintenance is:
Oil analysis.
b) Fuel analysis.
c) Measurement of vibrations.
. It is the type of maintenance that in the last quarter of the century
XX allowed for the maximum utilization of the equipment by
achieve a substantial reduction in machine downtime,
both programmed and unprogrammed, which in turn
allowed to implement economically systems such as
just in time
Corrective maintenance.
It is the sum of tasks that are carried out on a machine that has suffered.
a fault, with the aim of restoring its ability to fulfill its
Function. It is always necessary to take the machine out of service.
It is the oldest philosophy of this discipline: when it fails, it gets fixed, doesn't it?
respond to a programming and the following cases may arise:

. That the team remains in accordance with what has been defined as
SCHEDULED MAINTENANCE, it has a failure and is
make a CORRECTIVE.

. That the team remains according to what is defined as

SCHEDULED MAINTENANCE, and in an INSPECTION
PREDICTIVE finds itself in a situation such that it is decided
make a corrective.
. That the team does not have a scheduled maintenance plan
and a correction is made when it fails.

The CORRECTIVE can be carried out through two types of tasks:

. General tour.
. Minor maintenance.
The application of one type of task or another is the decision of the person in charge.
maintenance and depends on:
. Magnitude of the failure.
. Age of the machine that has failed.
. Operating cost.

General tour
It is the same concept explained in PREVENTIVE MAINTENANCE.
with the difference that it is not carried out according to a schedule but
when a failure has occurred. Logically, it applies when the failure is of
scope and the advisable thing is the general review of the equipment.

Minor maintenance
It is the repair of the failure without needing to make a RUN.
GENERAL, which logically consumes many fewer man-hours.
It is the daily work where there is poor preventive maintenance.

General comments on corrective maintenance.

. It is the oldest of the maintenances and is still synonymous with

this type of work.
. According to the magnitude of the failure or life of the equipment is the
decision on the type of task to apply, general route or
minor maintenance.
. Whether or not the equipment is undergoing MAINTENANCE
PROGRAMMED applies when there is a failure.

COMPARISON BETWEEN PREVENTIVE - PREDICTIVE MAINTENANCE -

CORRECTIVE.
Corrective QUOTE Predictive
Philosophy When the Machines equals The majority of the
break they should present abnormalities produce
fix it. wear and tear damage alterationof certain
equal in variable times, those that are evaluated,
equals. allow to know those.
Action The failure is expected measure, evaluate and quantify
and it is repaired. inspections in variable times.
prefixed.
Key to success Good technicians Good technicians and good technicians and quality of
and good workshop.quality of the measurement and exhaustive
information good knowledge of the
management of it and phenomena associated with
possibility of stopping the operation.
machine at the moment
indicated.
Synthesis Care Try to avoid Listen to the machine and try
to advance.
Give the idea of Repair. Verification. Study.
Advantages Only avoids costly breakdowns and safety, although lesser
when the bad is untimely. Higher than in the preventive. Avoid.
there is, security is generated. unnecessary disarmament. There is
costs in the face of a information permanent
bad thing. about the state of the
machines. It allows planning
better.
Disadvantages No avoid High cost due to disassembly Delay in fine-tuning.
breakdown what is inspections Misused can be
can be unnecessary. dangerous.
expensive e
inopportune. There is
invisible costs.
Application Total Very widespread, not applicable to machines whose
being applicable at cost y criticality the
machines whose cost justifies and that the time
repair shall be less between the potential failure and the
than that of prevention. do not be excessively
small.

Improvement and design change maintenance.

The so-called improvement maintenance consists of making improvements to

the geometry of the parts in order to further reduce breakdowns
redundant and improve the performance of the equipment in advance. It
difference of the corrective in that the changes of parts affect the design itself
of its internal geometry. It requires sophisticated engineering study of
maintenance to modify and correct designs and requires close
technical and practical cooperation between manufacturers and users of equipment. The
derogatory about the maintenance activities, whose content has been
traditionally manual in one service or another, to the world of offices
techniques at the very heart of industrial activity.

Any improvement process must ensure that responses are provided.

satisfactorily all of the following seven questions
oWhat are the functions and the ideal performance models of
resource in its current operational context (functions)?
oIn what ways can it fail to perform its functions (functional failures)?
oWhat causes each functional failure (modes of failure)?
oWhat happens when each failure occurs (effects of the failure)?
o In what way is each failure important (consequences of the failure)?
oWhat should be done to predict or prevent each failure (proactive tasks)
the work intervals)?
oWhat should be done if an appropriate proactive task cannot be performed?
found (default actions)?

If we analyze, we can find a great similarity to the criticality analyses,

and they will be an essential tool for improving reliability
operational allowing to establish the priorities of processes, systems and
assets, creating a structure that facilitates making sound decisions and
effective, directing effort and resources in areas where it is most
Important and/or necessary to improve operational reliability, based on the
current reality, clarifying that the cited norm does not allow for analysis only for
what is determined as critical, but a rigorous analysis must be done of
all teams, sub-teams, components, and in general all assets and
productive processes.

In conclusion, we can say that once again we find ourselves with

a methodology, process or philosophy, whatever you want to call it, that combines;
discipline, organization, and a lot of information, coupled with a good team of
work and a company commitment.

That is to say, there are other works that, while not responding orthodoxly to
what was defined as MAINTENANCE is included as such, since
normally it is this area of the organization that executes them.

In conclusion, it can be defined that:

Improvement Maintenance
It is the task that is carried out for the purpose of increasing the
maintainability of a unit or equipment, understood as
maintainability the characteristics of the unit, equipment or
support infrastructure that makes tasks of
maintenance be easier to perform.

An example of this type of maintenance would be:

. Construction of a platform that makes it more comfortable and safe

maintenance of a refrigeration unit installed at height.
. Open a registration door on a device enclosed in a structure.
metallic to facilitate and speed up a filter change.

DESIGN CHANGE
It is the task carried out to improve performance.
technical or economic of a unit or equipment.
An example of this type of maintenance would be:
. Replacement of a heat exchanger to reduce the
temperature of regime.
. Transformation of a gasoline engine to gas.

Quality, its relationship with maintenance.

Be part of one of the definitions of quality:
QUALITY
Set of properties and characteristics of a product,
process or service that gives you the ability to satisfy
established or implicit user needs, must
there is a balance between the mentioned quality, the price and the
offer.
It is evident that wear and tear in a production machine, which with a
adequate maintenance will be slower than without it, causing the
the magnitudes of the products she has crafted increasingly differ from
the design ones, or in other words, that lose quality.
If instead of a production machine it had been a producer of
services, e.g. a commercial airplane, maintenance that is correct in
As for ensuring the safety of the operation, it may not be so.
regarding having the aircraft in the right place and time to carry out the
benefit, which will cause the trip - the service, which is what is sold
It has been started with delay, or in other words, with a loss of quality. The
maintenance conferred reliability and safety, but not availability.
Conclusion: instead of just controlling quality, it must be generated.
there must be design quality and production quality, and for the latter, it is
necessary a good maintenance.

Costs, their relationship with maintenance.

A cost constancy, a loss of quality of the product or service, is a

implicit increase of those and this can be a consequence of a bad
maintenance; the same consequence follows from a failure as it is suspended.
the production or provision there is lost profit. It is evident then that a
Well-done maintenance results in lower costs.
Another consequence of proper maintenance is the increased lifespan of the
machines and equal to this at a higher residual value.
All of the above would give the following idea: good maintenance is synonymous with
decrease in costs; but be careful, maintenance is not free and how much
The more perfect one seeks to make it, the more expensive it will be.
It is common for businesses to demand maximum reliability and minimum cost.
the claim is logical, but it does not escape common sense that the greater
availability, reliability and security are intended, the more it will cost
maintenance.
It is absurd to expect maximum availability without maintenance, but be careful.
with going to the other side, it is not possible that with the desire to confer reliability
to affect production in order to ultimately maintain the
machines are for producing. As in everything, there is a point of balance that
It must be established beforehand between the one who wants to use the machine and
who makes it available, between those who produce and those who maintain, so much
availability as cost, less cost less availability.
If there is no preventive and predictive maintenance plan, or it is applied without
rigor, there will be little reliability and with it unexpected failures with
cessation of production or service and high cost of corrective maintenance
to which lost profits must be added. If, on the contrary, a
rigorous predictive and preventive plan will have high reliability with very few or
no unexpected failures and therefore low corrective costs and lost profits,
but the cost of preventive and predictive maintenance will be high. In summary, whatever it may be
the degree of reliability the maintenance cost will be the sum of the
preventive, predictive, corrective, and lost profits; the problem is defining whether the
required reliability is compatible with the resulting cost.

Ct: total cost

Cc: corrective maintenance cost plus

lost profits

Cp.:cost of preventive maintenance more

predictive maintenance

Ct = Cc + Cp.

It can be seen that the lowest part of the cost does not correspond to that of
greater reliability, but not the least. A common mistake is to assume
that maintenance costs decrease by not doing it; quite the opposite, no
doing maintenance is a temporary saving but over time it will result in more
expensive. Think about what the final cost could be of not doing it when appropriate,
the oil change in a car.

It is the responsibility of the person holding the highest position in the maintenance area.
properly advise the executives on this issue that should,
in this sense, knowing how to find the corresponding balance. In this regard,
You can advise but it is impossible to give rules, except for the three indicated plus.
down.
Three fundamental rules.
1. To always apply when planning maintenance.
FUNDAMENTAL RULE OF MAINTENANCE COST
All maintenance work carried out to prevent or
Predicting a failure must be at a lower cost than that of the
it would have generated if the failure that is to be avoided had occurred
occurred, except in cases where it affects the
security and/or the environment, in which case the work of
prevention or prediction must be carried out independently
of the cost.

2. Every well-organized company with a certain technological complexity

should, approximately, have this maintenance.

COST SEGMENT
COST
QUOTE............. 50%
COST
PREDICTIVE.............. 30%
COST
CORRECTIVE............ 20 %
3. Before planning the maintenance, the following must be done
rating of the teams and clearly identify A and C.

Equipment that does fail Equipment that does fail

TYPES OF EQUIPMENT does production cease or does production not cease
service or service
Teams to which the
maintenance the A B
confers reliability
Teams to which the
maintenance does not C D
confers reliability

PROACTIVE MAINTENANCE

Proactive maintenance involves the study of failures and analysis of the

maintenance activity, in order to draw conclusions and provide
Suggestions to improve the maintenance function.
The study of incidents and failure analysis is an activity related to the
machinery in general. The scheduling of this activity and its execution
it will depend on the company's criteria, based on the problems that arise
I want to analyze.

Working group.

A working group could be in charge of this activity, consisting of a

Maintenance Circle which is in turn led by those responsible for
maintenance. There can be several maintenance circles responsible
of different aspects of maintenance service or of different
system components.
The maintenance personnel will give the Maintenance Circles
specific problems to study, and they will be responsible for elaborating the
proposals and suggestions to solve the problems
The problem or event being analyzed is studied by the CM.
corresponding, for this the CM will be given all the necessary information.
The CM analyzes the problem and will obtain proposals for solutions regarding it.
which will be reflected in a proposal report of solutions.
This proposal for solutions is delivered to the maintenance manager or to the
fourth level of intervention.

If the proposals are not approved, the CM must analyze again the
problem.
If the proposals are accepted, they are presented to management, which approves them.
implementation of the proposal.
While the proposals are being implemented, the CM follows up on them.
implementation, under the supervision of the fourth level or of the responsible person
maintenance.

Proactive maintenance activities.

Among the activities carried out in proactive maintenance are

mainly:

Failure classification.- It starts with the preparation of a list of

possible failures or malfunctions that could occur: information obtained from
starting from the historical data and OT's from past administrations, ideas contributed by the
members of the working group, ideas obtained from questionnaires
answered by all members of Maintenance or Brainstorming,
events that occurred in other companies. After compiling the summarized list,
a Cause-Effect diagram, also known as
Ishikawa diagram, from which events can be classified.

Determination of resources for corrective maintenance.

The determination of resources for corrective maintenance consists of preparing

in advance, a list of necessary resources in case it arises
some type of failure that requires corrective maintenance intervention, in
in other words, it consists of knowing 'what needs to be on hand' according to the
case that arises. Based on the classification of possible failures as in the
From the previous section, a list of "symptoms" or data can be compiled that
they could have in case any failure occurred, previously
selected by the working group, then the resources are determined
necessary for addressing that failure, the same is done with other failures,
similar or not, then one can have a list of necessary resources for
corrective maintenance can be classified into corrective maintenances
in groups according to the resources they consume, and the most useful thing about this work is
that, according to the 'symptoms', it will be possible to know what resources are essential,
necessary and unnecessary.

Identification of the most frequent elements or events.

The study of incidents will allow us to identify those events or elements that
they present more frequently to prioritize their attention, and from this
way to study the reduction of its effects and incidences. For this, it is used
a tool called Pareto analysis. The Pareto method consists of
in a series of steps that culminate in the classification of events into classes of
priority. This analysis could help identify unnecessary expenses and not
detected, oversized expenses, worse especially when seeing the problems
which require greater attention, or immediate attention.

Rescheduling of activities.

Maintenance not only consists of following procedures and

recommendations, but it should also tend to be less
expensive in every management. Sometimes the scheduled time does not work out.
sufficient to carry out all the planned activities for a certain team or
circuit, this can be solved by increasing the scheduled time for the
interventions, or reducing the activities (tests) to be performed. The first
this is not very applicable in electrical systems, as it prolongs the
service interruption, which brings its respective consequences to the
company. The second case is more applicable, although it requires a study.
previously, it does not consist of the elimination of activities, but rather in the change of
frequency of their execution, that is to say that some activities
they could be held annually, and others with a different frequency, for example, tri
annual. Proactive maintenance in this case also acts as
quotation when determining the minimum and maximum acceptable times for the
carrying out certain tests on specific equipment. This analysis is performed
After carrying out the scheduled maintenance activities, it is a
process that requires time, even years, to obtain conclusions.

The advantages of rescheduling activities are that they reduce time and
preventive maintenance costs, since certain things do not have to be carried out
annual tests, the number of instruments and personnel is reduced
necessary for that activity.

Conclusions.
Maintenance in machinery becomes an important function within
of companies, due to proper maintenance, and the reduction
the prevention of failures will depend on the continuity of the service of
It is known that the failures of a system cannot be reduced to zero.
electric, but the important thing will be to avoid the occurrence of those failures that
they could have been prevented, especially those that could cause serious
breakdowns or the destruction of the equipment, due to their high cost and
in addition to the fact that its replacement or repair involves the mobilization of resources
humans and materials, with their consequent economic cost, not to mention the
service downtime and the fines this could imply. The
preventive maintenance, properly oriented, would be responsible for
prevent these consequences.
Still, in case of an incident that requires intervention from the
corrective maintenance, this must be carried out in an orderly manner and
efficient, to avoid delays due to unforeseen events and to manage to restore the service
as soon as possible, that is why it is necessary to plan the corrective maintenance,
although it is not possible to plan when and where a failure might occur or
a breakdown, if it is possible to plan how to be prepared for such eventuality,
regarding resources and procedures, it could even have software for
such purpose.
Maintenance is not static; like any engineering, it must be in
constant evolution, therefore, a maintenance management, applied to
any system must always be under analysis and review of
procedures, which is where proactive maintenance comes in, which,
through decision-making tools, procedures for analysis of
problems and proposed solutions in the formation of work groups
called Maintenance Circles, or through the function of
Planning and Development of Maintenance serve this purpose, the evolution
of Maintenance.
ORGANIGRAM OF INTEGRAL MAINTENANCE
VISUAL SYSTEMS

The Visual Systems for improving team effectiveness are a

extension of 'the visual factory' or 'the visual workplace'. While these
latest concepts focus on organization and order in the area of
I work to eliminate waste and errors, the visual signals
applied to the equipment really makes it easier to operate, maintain and
inspect

On the Team

• Marking the appropriate ranges on temperature indicators,

pressure, flow, and velocity.
• Labeling the team components in order to eliminate the mystery and
maintain an accurate repair history
• Labeling lubrication points and liquid filling points
• Marking the direction of flow, feed, or rotation to avoid
installation and connection errors
• Applying temperature-sensitive labels at critical points of the
machines that allow 24-hour visual monitoring of
hydraulic components, electrical components, bearings, motors, etc.
• Using grease trap lids with color codes indicating type of
fat and frequency
• Installing reading discs and indicator labels for the points of
reading for vibration analysis in order to achieve repeatability.
• Labeling band #, filter, chain measurements, and part numbers
about the equipment to save time on maintenance
• Establishing color code for tools and parts that must be
change when changing product
• Using problem cards to clearly mark the
requirements and maintain a visual reminder on the 'board of
action
• Labeling pneumatic lines and devices to expedite location
of failures.
• Labeling cables in panels and devices to facilitate location.
of failures.
• Marking nuts and bolts to visually indicate that they are
maintaining its original proper position and adjustment
• Labeling the inspection points and sequential numbers for the
reading of indicators

Visual Processes and Work Instructions

• Photographs and small drawings to show points and processes

important
• Photographs showing where to inspect or readjust
• Photographs showing where to take readings for the sheet of
shift record