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1
TYPES OF MAINTENANCE
OF
INDUSTRIAL PHARMACY
By: Jessica Fernandes
Reg. No. 150617004
Department of Pharmaceutics
Guided By: Dr. Usha Nayak
Maintenance Classification
 Corrective or Breakdown Maintenance
 Scheduled Maintenance
 Preventive Maintenance
 Predictive Maintenance
2
3
Types of
Maintenance
Correctiv
e
Predictive
Preventiv
e
Scheduled
1. Corrective Or Breakdown
Maintenance
• “Repairs that are made after the equipment is
out of order and it cannot perform it’s normal
function any longer”
• Eg: Electric Motor will not start
• Used in small factories which get temporary
remand in excess of normal operating capacity
4
Conditions
Production
Department
Maintenance
Department
Necessary
Repairs
No further
maintenance until
next breakdown
5
6
Causes For Equipment
Breakdown
Failure to
replace worn
out parts
Lack of
Lubrication
Neglected Cooling System
External Factors
Indifference towards minor faults
Indifference towards major faults
7
Advantages of Breakdown
Maintenance
8
Lower Initial Costs
Requires Fewer Staff
No Planning Needed
9
Disadvantages of Breakdown
Maintenance
10
Reduction of
Output
Faster Plant
Deterioration
Increased Chances
of Accidents
More Spoilt
Material
Direct Loss of
Profit
Breakdown at
Inopportunate
Times
Plant Items Regulated
by Statutory
Provisions are not
subject to breakdown
maintenance
11
12
Types of
Maintenance
Correctiv
e
Predictive
Preventiv
e
Scheduled
2. Scheduled Maintenance
• Aim: Avoiding Breakdown
• Scheduled maintenance incorporates:
13
• Lubrication• Inspection
White
washing of
buildings
Overhauling
of machines
Cleaning Of
Water &
Other Tanks
Repair
14
Types of
Maintenance
Correctiv
e
Predictive
Preventive
Scheduled
3. Preventive Maintenance
Principle: Prevention is better than cure
• Aims at minimising the problems of breakdown
maintenance
• Locates Weak Spots
• Provides Regular inspection
• Initiates minor repairs thereby reducing the risk of
unanticipated breakdown
15
Objectives
16
Minimizing the possibility
of unanticipated
production interruption.
Make plant equipment and
machinery always
available and ready for use.
Maintain optimum
productive efficiency of the
equipment. 17
Maintain operational
accuracy.
Reduce work content of
maintenance jobs.
Achieve maximum production
at minimum repair cost.
Ensure safety of life of the
workmen. 18
Elements/Procedure of PM :
• Who should do PM?
• Where to start PM?
• What to inspect in PM?
• What to inspect for ?
• How often to inspect ?
• When to inspect- schedules ?
• Preventive maintenance records
• Control and evaluation of PM
19
Who should do PM?
20
Production
department.
Maintenance
department.
A separate
division of
inspectors
and
supervisors.
21
Where to start PM?
• PM should not be done for the entire plant at
once
• It is better to tackle one department or
machinery at a time
• The entire PM programme hangs on
inspections and their related duties of
adjustments and repairs
22
What to inspect in PM?
• All industries have certain key items which are
more essential for continuing the production than
others
• key items are :
 Material handling equipment
 Safety equipment
 Process equipment
 Special purpose – unique equipment and machines
 Water , air and fuel lines
23
What to inspect for ?
• After listing the equipment requiring PM , the
next step is to decide – what physical parts of
each piece of equipment need attention
• After making the list of machines and their
parts needing PM , a CHECK – LIST to ensure
that no inspection point has been missed is
made
24
How often to inspect ?
• Based on :
 Past experience
Cost and savings
• Over inspection Expensive
• Under inspection More breakdown
25
When to inspect- schedules ?
• Scheduling involves determining calendar
inspection dates that will fulfil the frequency
requirements in the most efficient way
• In setting up schedule one must ensure to keep
production going at lowest overall cost
• Schedules should be set in consultation with
production department and as per the production
needs , as far as possible
26
Preventive maintenance
records
27
Record should show -
• Type of equipment and description
• Whether it is a key item?
• Name of the manufacturer
• Cost and date of purchase of the equipment.
• Location of the equipment in the factory
28
• Equipment identification number
• Estimated cost of inspection and the cost and
data of planned repairs
• Breakdowns , their dates and reasons
• Cost of breakdowns and other associated
implications
29
Control and evaluation of PM :
• To maintain control of the PM programme ,
the following measures should be taken :
I. Periodic review of PM programme with the
operating department
II. Review of monthly reports of PM inspections
III. Analytical approach to the evaluation of PM
30
• Analytical approach makes use of following
relations :
a)
𝐼𝑛𝑠𝑝𝑒𝑐𝑡𝑖𝑜𝑛𝑠 𝑖𝑛𝑐𝑜𝑚𝑝𝑙𝑒𝑡𝑒
𝐼𝑛𝑠𝑝𝑒𝑐𝑡𝑖𝑜𝑛𝑠 𝑠𝑐ℎ𝑒𝑑𝑢𝑙𝑒𝑑
×100 = 10% Max
b)
𝐻𝑜𝑢𝑟𝑠 𝑤𝑜𝑟𝑘𝑒𝑑
𝑇𝑜𝑡𝑎𝑙 ℎ𝑜𝑢𝑟𝑠 𝑤𝑜𝑟𝑘𝑒𝑑
×100= Percentage of performance
Good
updated
records.
Adequate
clerical
help.
Proper
filing
equipment.
32
Advantages
• Reduced breakdowns and connected down-time
• Lesser odd-time repairs and reduced overtime to
the maintenance work-force
• Greater safety for workers
• Fewer large-scale and repetitive repairs
• Low maintenance and repair costs
• Less stand-by or reserve equipment, and spare
parts
33
34
Types of
Maintenance
Correctiv
e
Predictive
Preventiv
e
Scheduled
Predictive Maintenance
• New technique
• Extends service life of equipment without
failure
• Makes use of human or other sensitive
instruments like:
35
Pressure
Amplitude
meters
Temperature
Audio
Gauges
36
References
• Khanna OP, Industrial Engineering and
Management, 1st Edition 1992, Page no:
13.5-13.12
37
38

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