notes

1. ROUTINE MAINTENANCE
Usually a small scale activity to keep a piece of machinery or equipment in good working order.
Popular Terms
Simple, small-scale activities (usually requiring only minimal skills or training)
associated with regular (daily, weekly, monthly, etc.) and general upkeep of a
building, equipment, machine, plant, or system against normal wear and tear.
Attributes
Routine maintenance has the following general attributes that distinguish it from other forms of maintenance:
 The routine is most commonly based on fixed intervals of time, such as “every
x hours of machine time”, “every x days”.
 It usually occurs quite regularly, since as daily, weekly, monthly or quarterly.
 The routine activities are funded from the annual operating budget.
 Depending on the type of building, it represents anywhere from 10-30% of the
operating.
 Many of the tasks are performed by contractors under a service
agreement and is therefore a form of planned maintenance.
 The majority the routine maintenance tasks are performed as time-based
maintenance (TbM).
 It is proactive in nature.
ExampleTasks
Examples of routine maintenance activities typically include some of the following:
 Steam cleaning of the carpets (once a year)
 Washing of the windows (every six months)
 Lubricating of the pumps (yearly)
 Mopping of the floors (daily)
 Mowing of the lawns (weekly during the growing season)

2. Planned maintenance
Planned preventive maintenance (PPM), more commonly referred to as simply planned
maintenance (PM) or scheduled maintenance, is any variety of scheduled maintenance to an
object or item of equipment. Specifically, planned maintenance is a scheduled service visit carried
out by a competent and suitable agent, to ensure that an item of equipment is operating correctly
and to therefore avoid any unscheduled breakdown and downtime.[1]
Along with condition-based maintenance, planned maintenance comprises preventive
maintenance, in which the maintenance event is preplanned, and all future maintenance is
preprogrammed. Planned maintenance is created for every item separately according to
manufacturers recommendation or legislation. Plans can be date-based, based on equipment
running hours, or on the distance travelled by the vehicle. A good example of a planned
maintenance program is car maintenance, where time and distance determine fluid change
requirements. A good example of condition-based maintenance is the oil pressure warning light
that provides notification that you should stop the vehicle because engine lubrication has stopped
and failure will occur.
Planned maintenance has some advantages over condition-based maintenance (CBM), such as:
 easier planning of maintenance and ordering spares,
 costs are distributed more evenly,
 no initial costs for instruments used for supervision of equipment.
Disadvantages are:
 less reliable than equipment with fault reporting associated with CBM
 more expensive due to more frequent parts change
 requires training investment and ongoing labor costs
Parts that have scheduled maintenance at fixed intervals, usually due to wearout or a fixed shelf
life, are sometimes known as time-change interval, or TCI items.
Planned maintenance, also known as planned preventative maintenance or scheduled
maintenance, is an activity where a company will schedule work done in order to avoid outages.
The simplest example of this for the average person is an oil change on their car. The oil is
changed on a regular basis to prevent the engine from having problems at an unexpected
moment in the future.
Facilities need to have a detailed planned maintenance program to ensure all their machines and
other equipment are working properly as much as possible. When a good planned maintenance
program is in place, facilities are also better able to have a predictable set of expenses. The costs
of most types of maintenance are known, whereas repairing costs for something after it is broken
is often unpredictable.
Who Does Planned Maintenance?
One of the benefits of planning maintenance activities ahead of time is you can schedule experts
to perform the work. If a machine breaks down unexpectedly, the person who is best able to fix it
might not be working that day. This can make it much more difficult to complete the repair, and it
may take far longer.

3. By planning maintenance weeks, months, or even years in advance, it is possible to ensure the
right people are there to do the job. It also allows them to make sure they have the right tools,
parts, and equipment to get it done right.
Types of Planned Maintenance
There are many types of planned maintenance that the average workplace performs. Something
as simple as general cleaning can be considered a type of maintenance, since removing dirt and
debris from an area can help avoid problems with many types of machinery. Some other types of
planned maintenance include:
 Lubrication – Most machines require lubricants to keep things running smoothly.
Replacing the oil or other lubricant on a regular basis helps avoid many mechanical
problems.
 Parts Replacement – Some parts are designed with a set lifespan. A saw blade, for
example, will wear out after a set amount of time. If the blade is not replaced on a
schedule, it will begin to cut less efficiently. This can also result in cuts that aren’t ‘clean.’
 Upgrades – Part of many planned maintenance plans is upgrading equipment. Keeping
things up to date with the latest options can help improve the safety and efficiently of
machines. Planning upgrades on a schedule like this also allows for predictable
expenses.
Disadvantages of Planned Maintenance
While planned maintenance offers many benefits to facilities, there are also some drawbacks that
need to be addressed. One potential issue is that companies will be replacing parts according to
a set schedule rather than when it is strictly needed. Many parts have set ‘life expectancies’
assigned to them, but may actually last significantly longer. Some companies inspect parts before
replacing them and plan future maintenance accordingly.
Another issue is that while planned maintenance is less expensive than waiting for a major issue
to occur, it can be more expensive than using fault reporting strategies. Having systems alert
when there are signs of an issue and then performing the maintenance, can sometimes save
money in the long run. It must be done precisely to avoid potential problems.
scheduled maintenance
Definition
Popular Terms
Level of maintenance that requires planning, allocation of significant amount of time, and high
degree of coordination between different departments, and is typically initiated through a work
order.
Read more: http://www.businessdictionary.com/definition/scheduled-maintenance.html

4. Breakdown Maintenance
Definition - What does Breakdown Maintenance mean?
Breakdown maintenance is a form of material or equipment remediation that is performed after
the equipment or material has lost its functioning capabilities or properties. Breakdown
maintenance is often the last resort in an attempt to restore or extend the life of a given asset.
Breakdown maintenance is maintenance performed on equipment that has broken down and is
unusable. It is based on a breakdown maintenance trigger. It may be either planned or it can be
unplanned.
Breakdown Maintenance and Unscheduled breakdowns
Breakdown Maintenance is referred to repair and maintenance work performed on a machine,
production plant or component, be it mechanical or electrical after it has failed or broken-down
unexpectedly. It is also referred to as maintenance or engineering work related to unforseen plant
breakdowns. It is not a planned event and as such can cost the factory lost production and sales as
well as other expenses such as out of budget maintenance costs including overtime, technician call
outs and urgent delivery fees for spare parts or support.
Maintenance breakdowns can have many causes, some being the result of improper preventive and
long term maintenance planning, lack of plant inspections, lack or incorrect evaluation of stresses
and load cycles on machinery, faulty design and materials and in some cases neglect.
A proper maintenance plan, correct documentation, record keeping and maintenance execution at
the correct intervals usually aids the maintenance or engineering department to eliminate the
majority of unforseen breakdowns.
Unforseen plant breakdowns can be classified as a form of waste in the lean manufacturing system as
they waste both time and resources . This indirectly costs the business financially as budgeted
maintenance costs are used for unforseen costs and work as well as lost production which is lost
revenue for the business. It is therefore important to eliminate or reduce breakdown maintenance
to minimal levels to maximize production output and operational costs.
How to reduce Unscheduled breakdowns and reduce breakdown maintenance costs
Moving away from breakdown maintenance or reactive maintenance takes both time and a change
in culture of the operations and engineering team. In many smaller businesses with little exposure
to efficient planning and engineering practices, breakdown maintenance is the only maintenance
“style― or system the team understands or has practiced. Changing this culture and method
of work will take commitment from the highest levels of the business to the production and
maintenance technicians that work in the factory every day.

5. A common starting point is to think about the airline industry, where preventive maintenance is the
only maintenance system acceptable by the industry and the consumer. Would it be acceptable to
wait until a wing component has failed to replace it? What would be the consequences? This is the
type of thinking that needs to be introduced to the maintenance and the production teams, as they
are the individuals that detect problems while the plant and machinery is in operation.
Another initial action would also be for the plant manager and maintenance manager to evaluate
the unforseen breakdowns in the entire production plant, or depending on size the most business
critical or breakdown prone area of the plant. An initial analysis can include the last three to six
months of breakdowns and plant failures which resulted in production downtimeproduction downtime
of more than one hour. Most minor issues should be able to be rectified within an hour in most
cases. The area or machine with the largest share of production downtime hours should be the
focus of the maintenance team. An interesting analysis which can be done in parallel is to quantify
the actual cost of the unforseen breakdowns to the business in this area.
Once the priority area or plant item has been defined the following questions or items should be
reviewed and rectified about the plant in question. This will help the area transition from a reactive
breakdown maintenance approach to a preventive mode:
- Is the machine or plant item in question operating within its design capacity and load?
For example a conveyor belt may be running overloaded or with an incorrect belt for the
application
- Is there a fault in the design of the machine or plant?
For example the conveyor was purchased from an economical source which has substandard
bearings and large distance between the load bearing rolls
- Is there an engineering drawing for the machine or plant which has frequent
breakdowns? Are all parts or components also correctly specified in the drawing
- Is there information about the plant and spare parts that will enable quick look up,
ordering and cost budgeting for maintenance work?
For example well run maintenance departments will have a complete catalogue of all plant,

6. machinery and spare parts which will have identifying component numbers, drawings, supplier or
manufacturer, and pricing information including lead time.
- Is there a lubrication and inspection schedule for the plant or machine? In some cases
a maintenance or production team member will be allocated inspection ownership of an
area
- Are spare parts for this plant area or machine available in the parts store or workshop?
Is it economical to purchase and store spare parts for this plant, do suppliers have
maintenance support and spare parts services?
- Is the plant kept in a clean and good working order each day? Early wear on machine
components is sometimes due to poor housekeeping standards
- Are auxiliary systems to plant in good working order?
For example generators and compressors need large cooling systems and fans to keep them from
overheating during long working hours. These can also be temperature, humidity, pressure and
speed controls.
- Is the maintenance history available for this plant or area? When was the last
preventive maintenance carried out on the machine or plant?
- Does the maintenance staff knows how to maintain or fix the plant or machine, is
specialists skills needed?
Reviewing and ensuring the correct solutions for the issues above are in place will better prepare
the maintenance and engineering team to first improve the reliability of the plant and machine in
focus, and then enable a more preventive maintenance routine to be established. In our experience
this can also be a a large task or even project, depending on the state of the plant and size. It is
best to select a small high priority area first to realistically achieve sustainable results.