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  • 1. Maintenance Types and Procedures
  • 2. What is maintenance? • It is 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 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.
  • 3. Is it only cleaning and washing?
  • 4. Maintenance Objectives • • • • • Reducing breakdowns and emergency shutdowns. Optimising resources utilisation. Reducing downtime. Improving spares stock control. Optimising the useful life of equipment.
  • 5. Breakdown Maintenance • The required repair, replacement, or restore action performed on a machine or a facility after the occurrence of a failure • The failure of a component in a system is unpredictable. • It is the oldest type of maintenance ADVANTAGES • Complete use of material and machine • The cost of performing this type of maintenance activities is lower than performing other types of maintenance.
  • 6. Preventive Maintenance • The maintenance carried out at predetermined intervals or according to prescribed criteria and intended to reduce the probability of failure • It is good for those machines and facilities which their failure would cause serious production losses. ADVANTAGES • Breakdowns and emergency repairs are minimised. • Increased component’s life • Annual production capacity can be exactly estimated
  • 7. Corrective Maintenance • 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. • 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.
  • 8. Contd... ADVANTAGES • Maximisation of the effectiveness of all critical plant systems • Elimination of breakdowns. • Elimination of unnecessary repair.
  • 9. Design-out maintenance • Set of activities that are used to eliminate the cause of maintenance, simplify maintenance tasks. • Raising machine performance from the maintenance point of view by redesigning those machines and facilities which are vulnerable to frequent occurrence of failure
  • 10. Opportunity maintenance • 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. ADVANTAGES • Separate time for maintenance activities for such machines need not be scheduled • Effective usage of man power and energy
  • 11. Condition-based predictive maintenance • Depends on continuous or periodic condition monitoring equipment to detect the signs of failure. • Example : Boilers – Hairline cracks
  • 12. Reliability Centred Maintenance • It is a process used to determine the maintenance requirements of any physical asset in its operating context. • Able to focus maintenance activities on critical components. • Example : Nuts and bolts of ladders are of least importance when compared to baffles of large distillers.
  • 13. Total Productive Maintenance • Total Productive Maintenance (TPM) is a maintenance program which involves a newly defined concept for maintaining plants and equipment. • The goal of the TPM program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction.
  • 14. Objectives of TPM • TPM was introduced to achieve the following objectives. – Avoid wastage in a quickly changing economic environment. – Producing goods without reducing product quality. – Reduce cost. – Produce a low batch quantity at the earliest possible time. – Goods sent to the customers must be non defective.
  • 15. It is only the tip of the iceberg!
  • 16. Procedures for Maintenance • Maintenance Planning
  • 17. • Performing Maintenance activities • Inspecting work done • Evaluating Maintenance
  • 18. Quiz • What type of maintenance does the following need? 1. Nuclear reactor 2. Car manufacturing unit 3. Aeroplane 4. Ship
  • 19. That is it!!!