MAINTENANCE

ENGINEERING
Lecture I
 INTRODUCTION TO
MAINTENANCE
Its Scope & Types

(Credit to Engr. Kamal Zafar, Lecturer,

Department of Chemical Engineering, UOG)
Learning Objectives
• After completion of this section, you will be able
to:
• Describe brief historical background of
maintenance
• Define maintenance
• Explain the need of maintenance in industry
• Outline the main objectives of maintenance in
an industry
• Describe various types of maintenance and 3
their pros and cons
Maintenance History

Term terotechnology-
.introduced
-Recognition of need to -Increased awareness of:

prevent equipment
-Environment
-Safety
-Quality
Development of

-Need for reliable equipment.

failures.
-Reduction in costs.
Maintenance

-Models for preventive

maintenance developed.
Fix the equipment when it breaks

Time

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

Figure: Maintenance History

(Adapted From Shenoy, Bhadury
1998)
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HOW MAINTENANCE
EFFECT
• Maintenance effect reliability
• Maintenance effect product quality
• Maintenance effect productivity
• Maintenance effect safety
• Maintenance effect supply chain,
• Failure cause disruption, waste, accident,
inconvenience and expense.
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• Operators less able to do repairs
themselves (unscheduled & unplanned)
• Machine and product failure can have
effect on company’s operation and
profitability
• Idle workers, facility
• Losses due to breakdown
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FAILURE
• Failure – inability to produce work in appropriate
manner
• Example:
• Equipment / machine failure on production floor:
• – worn out bearing, pump, pressure leaks, broken
shaft, overheated machine etc.
• Equipment failure in office:
• – failure of power supply, air-conditioned system,
computer network, photocopy machine
• Vehicle failure:
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• – brake, transmission, engine, cooling system
MAINTENANCE IN SERVICE
INDUSTRY
• Hospital
• Restaurants
• Transport companies
• Banks
• Hotels and resorts
• Shopping malls / retail
• Gas station
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MAINTENANCE IN
MANUFACTURING INDUSTRY
• Electronic
• Automotive
• Petrochemicals
• Refinery
• Chemicals
• Ceramics
• Food and beverages
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MAINTENANCE
• All actions necessary for retaining an item,
or restoring to it, a serviceable condition,
include servicing, repair, modification,
overhaul, inspection and condition
verification
• All activities that maintain facilities and
equipment in good working order so that a
system can perform as intended.
• Increase availability of a system
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• Keep system’s equipment in working order
Question!
• Why do we need maintenance?
• What are the costs of doing maintenance?
• What are the costs of not doing
maintenance?
• What are the benefits of maintenance?
• How can maintenance increase
profitability of company?

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Scope of Responsibilities
• Actual maintenance practice may be to a specific
facility, a specific industry, and a specific set of
problems and traditions
• Maintenance of Existing Plant Equipment
• Maintenance of Existing Plant Buildings and
Grounds
• Equipment Inspection and Lubrication
• Alterations and New Installations
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PURPOSE OF
MAINTENANCE
• Attempt to maximize performance of
production equipment efficiently and
regularly
• Prevent breakdown or failures
• Minimize production loss from failures
• Increase reliability of the operating
systems.
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PRINCIPLE OBJECTIVES IN
MAINTENANCE
• To achieve product quality and customer
satisfaction through adjusted and serviced
equipment.
• Maximize useful life of equipment.
• Keep equipment safe and prevent safety hazards.
• Minimize frequency and severity of
interruptions.
• Maximize production capacity – through high
utilization of facility.
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PROBLEMS IN
MAINTENANCE
• Lack of management attention to
maintenance.
• Little participation by accounting in
analyzing and reporting costs.
• Difficulties in applying quantitative analysis.
• Difficulties in obtaining time and cost
estimates for maintenance works.
• Difficulties in measuring performance.
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PROBLEMS EXIST DUE TO:
• Failure to develop written objectives and
policy.
• Inadequate budgetary control.
• Inadequate control procedures for work order,
service requests etc.
• Infrequent use of standards to control
maintenance work.
• Absence of cost reports to aid maintenance
planning and control system.
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Maintenance Objectives

1. The equipment or facilities are always kept in an

optimum working condition with minimum
operating cost.
2. The time schedule of delivery to the customers is
not affected because of the machinery/ service.
3. The performance of the machinery/ facility is
reliable.
4. The downtime of machinery/facility is kept to
minimum in the event of breakdown.
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Maintenance Objectives (cont...)

5. The maintenance cost is properly monitored to

control the overhead costs.
6. The life of the equipment is prolonged while
maintaining the acceptable maintenance level of
accuracy of performance to avoid unnecessary
replacements.
7. The maintenance standards in terms of quality
must be kept to achieve the desired reliability.

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Maintenance Objectives (cont...)

8. The maintenance records keeping and

function evaluation should be taken care of.
9. The clean and hazard free maintenance
facilities are made available.
10. The effective maintenance inventory of spare
parts is maintained at each level.

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Maintenance Objectives

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MAINTENANCE COSTS
• Cost to replace or repair
• Losses of output
• Delayed shipment
• Scrap and rework

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TYPES OF MAINTENANCE
• Maintenance may be classified into four
categories:
• (some authors prefer three categories- scheduled
and preventive maintenances are merged)

1. Corrective or Breakdown maintenance

2. Scheduled maintenance
3. Preventive maintenance
4. Predictive (Condition-based) maintenance 22
CORRECTIVE OR
BREAKDOWN MAINTENANCE
• Corrective or Breakdown maintenance implies
that repairs are made after the equipment is
failed and can not perform its normal function
anymore

• Quite justified in small factories where:

• Down times are non-critical and repair costs
are less than other type of maintenance
• Financial justification for scheduling are not
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felt.
DISADVANTAGES OF
CORRECTIVE MAINTENANCE
• Breakdown generally occurs inappropriate times leading to
poor and hurried maintenance
• Excessive delay in production & reduces output
• Faster plant deterioration
• Increases chances of accidents and less safety for both
workers and machines
• Direct loss of profit.

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SCHEDULED MAINTENANCE
• Scheduled maintenance is a stitch-in-time procedure and
incorporates
• inspection
• lubrication
• repair and overhaul of equipment
• If neglected can result in breakdown
• Generally followed for:
• overhauling of machines
• changing of heavy equipment oils
• cleaning of water and other tanks etc.
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PREVENTIVE
MAINTENANCE (PM)
• Principle – “Prevention is better than cure”
• It
• locates weak spots of machinery and
equipment
• provides them periodic/scheduled
inspections and minor repairs to reduce the
danger of unanticipated breakdowns
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 ADVANTAGES OF PM
• Advantages:
• Reduces break down and thereby down time
• Less odd-time repair and reduces over time of crews
• Greater safety of workers
• Lower maintenance and repair costs
• Less stand-by equipment and spare parts
• Better product quality and fewer reworks and scraps
• Increases plant life
• Increases chances to get production incentive

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PREDICTIVE (CONDITION-BASED)
MAINTENANCE

• In predictive maintenance, machinery conditions

are periodically monitored and this enables the
maintenance crews to take timely actions,
such as machine adjustment, repair or overhaul

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PREDICTIVE MAINTENANCE
(CONTD.)
• It makes use of human sense and other sensitive
instruments, such as
• audio gauge, vibration analyzer, amplitude meter,
pressure, temperature and resistance strain gauges etc.
• Unusual sounds coming out of a rotating equipment
predicts a trouble
• An excessively hot electric cable predicts a trouble

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