Maintenance Types, Process, schedule, reducing failures, etc for engineers. 1. helps in interview preparation. 2. helps in knowledge boosting. 3. helps in seminar preparation. 4. helps in fault minimization. 5. helps in increasing machine performance. etc.

1. Understanding Maintenance
Process For C &I Engineer
Trainer :- D. Chakraborty , C & I - Dept
C & I Enginner Knowledge Boosting Program -2 , 29.07.2020

2. Why do you clean your house daily ?
Why do you service your car or bike ?
Why do you saloon your hairs & nails ?
Why do you oil your door locks ?
Why do you clean your garbage from mobiles?
Why do you clean the blades of your ceiling fan and other home appliances ?
The one word solution for all of the above questions is

3. MAINTENANCE

8. Failure – Inability to produce work in appropriate manner
 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 – brake, transmission, engine, cooling system
What is Failure

9. What failure prevention strategies should be adopted by
Engineer’s / Technicians to –
1. Reduce Breakdown of Equipment’s
2. Increase the longevity of Equipment's
3. Increase safety of Man & Machine
4. Minimize Maintenance Cost
5. Improve Quality of Products

10. TO STOP FAILURES WE MUST ADOPT THE FIVE TYPES OF
MAINTENANCE
• Breakdown maintenance or corrective maintenance
• Preventive maintenance
• Predictive maintenance ( Condition Based)
• Routine maintenance
• Planned maintenance

11. Reactive maintenance is the process of repairing assets to standard operating
conditions after poor performance or breakdown is observed. The primary benefits
of reactive maintenance are; lowers costs and it requires less staff to implement.
Corrective maintenance comes under reactive maintenance.

12. Corrective or Breakdown maintenance implies that repairs are made after
the equipment is failed and can not perform its normal function anymore.
Disadvantages
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

13. Principle – “Prevention is better than cure”
Procedure - Stitch-in-time
It is undertaken before the need arises and aims to minimize the possibility of
un -anticipated production interruption or major breakdowns.
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's and spare parts
 Better product quality and fewer reworks and scraps
 Increases plant life

14. 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
o 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.
o Unusual sounds coming out of a rotating equipment predicts a trouble
o An excessively hot electric cable predicts a trouble.
o Simple hand touch can point out many unusual equipment conditions and thus predicts
a trouble

15. This includes activities such as periodic inspection,cleaning,lubrication and
repair of production equipment's after their service life.
Routine maintenance is designed to help keep equipment, machines, and buildings
operating optimally. If a particular piece of equipment needs lubrication, it may work at
a slower rate and reduce the efficiency of an entire line. If dirt interferes with a certain
component, an entire production line can be shut down until the problem is identified.
Lubricating and cleaning equipment on a regular schedule prevents such problems.
Advantages
 Routine maintenance prevents larger problems from occurring.
 Routine maintenance increases efficiency of equipment
 Minimizes down times

16. Planned maintenance is the process of detailing what materials, tools, tasks, and services are
required to solve a problem. The purpose of planned maintenance is to determine what work
needs to be completed and how it needs to be done.
Planned maintenance starts with a problem and identifies the materials, tools, and tasks
necessary to work on the problem. The planning process involves inspections, part ordering,
process descriptions, and work prioritization.