The document discusses the functions and types of maintenance programs. It aims to ensure equipment is available for operation in a satisfactory condition. There are three main types of maintenance programs: corrective, preventive, and predictive. Corrective maintenance involves repair work after a failure. Preventive maintenance is time-based and focuses on inspections, servicing, and minor repairs. Predictive maintenance uses condition monitoring to detect issues and schedule maintenance as needed to avoid breakdowns. The goal is to maximize equipment availability and performance at optimal costs.

1. FUNCTION OF MAINTENANCE
- The function of maintenance is to ensure that plant
and equipment are available in a satisfactory condition for
operation when required
- Satisfactory condition for the rotating machinery depends
on
1. Type of industry ( determine the level of machine
performance required)
2. Process requirement ( the requirement of a machine
that is critical to the process will be greater one for than
non critical)
3. Business objectives product demand and profit levels
fluctuating demands on equipment and performance
requirements
The performance of maintenance function can be judged by the
condition of machinery and by the following factors
1. Performance: machines must be capable of performing the
function
2. Downtime: machine must operate with acceptable level of
downtime
3. Service life: machines must provide a satisfactory return on
investment
4. Efficiency: machine must operate with safety accuracy
productivity and minimum power loss
5. Safely: machine must operate safely and not dangerous to
personnel
6. Environmental impact: machine must operate in a manner
to adjacent plant and equipment
7. Cost: the cost of maintenance must be acceptable

2. Maintenance programs
There are three types;
1. Corrective maintenance (CrM)
2. Preventive maintenance (PM)
3. Predictive maintenance (PdM)
Corrective maintenance: defined as the remedial action
carried out due to failure or deficiencies discovered during
preventive maintenance to repair an equipment to its
operational state
the activities of corrective maintenance? Explain with an
example.
1. fail-repair:
The failed item is restored to its operational state.
2. Salvage
This element of corrective maintenance is concerned with
disposal of non repairable material.
3. Rebuild:
This is concerned with restoring an item to a standard as
close as possible to original state.
4. Overhaul:
Restoring an item to its total serviceable state as per
maintenance serviceability standards.

3. 5. Servicing:
servicing may be needed because of the corrective
maintenance action for example engine
Fail repair
Salvage Types of Overhaul
CrM
Servicing Rebuild
o

4. The advantage and disadvantages of corrective
maintenance
Advantages:
1. Low cost.
2. Less staff.
Disadvantages:
1. Increased cost due to unplanned downtime.
2. Increased labor cost.
3. Cost involved with repair.
4. Possible secondary equipment.
5. Inefficient use of staff resources
Preventive maintenance (PM) ( time – based)
Preventive maintenance can be defined as: actions
performed on a time or machine run based schedule that
detect delay or mitigate degradation of a component
Advantages
Cost effective in many capital intensive processes
Flexibility allows for the adjustment of maintenance
periodicity
Increased component life cycle
Energy saving
Reduced equipment failure
Cost savings

5. Disadvantages
Catastrophic failures still likely to occur
Labor intensive
Include performance of unneeded maintenance
Potential for incidental damage to components in
unneeded maintenance
main activities of preventive maintenance
1. Inspection. To determine their serviceability
2. Servicing. Cleaning, lubricating, charging
3- Calibration periodically determining the value of
characteristics of item
4. Testing. Periodically testing or checking out to
determine serviceability and detect degradation
5. Alignment. Making change to achieving optimum
performance
6. Adjustment. Periodically adjusting specified
variable elements of material for the purpose of
achieving the optimum performance
7. Installation. Periodic replacement of limited life
item to maintain the specified system tolerance

6. INSPECTION
SERVICING
ADJUSTMENT
CALIBRATION
ELEMENTS OF PM
ACTIVITIES
ALIGMENT
INSTALLATION
TESTING

7. Predictive Maintenance (PM)
( based on quantified material/ equipment condition
Measurements that detect the onset of a degradation
mechanism results indicate current and future functional
capability
Difference between predictive maintenance and
preventive maintenance by using maintenance need on
the actual condition of the machine rather than on some
preset schedule
Advantages of predictive maintenance
1. Increased component operational life.
2. Allows for preemptive corrective actions.
3. Decrease in equipment or process downtime.
4. Decrease in costs for parts.
5. Better product quality.
6. Improved worker and environmental safety.
7. Improved worker moral.
8. Energy savings.
9. Estimated 8% to 12% cost savings over pm program
Disadvantages of predictive maintenance
1. Increased investment in diagnostic equipment.
2. Increased investment in staff training.
3. Savings potential not read.

8. Pro- active maintenance
Uses a variety of technologies to extend the operating
lives of machines and to virtually eliminate reactive
maintenance (root cause failure analysis)
Benefit:
1. Resulting in greatly extended machine life.
2. Reduced down time.
3. Expanded production capacity
BASIC MAINTENANCE STRATEGIES
Reactive (Fix it when it breaks)
Benefit (zero initial investment)
Scheduled (change it out every-------- hours)
Benefit (reduced catastrophic breakdown)
Condition (does it need to be fixed)
Based (CBM)
Benefit (maintenance done when needed)

9. PREVENTIVE MAINTENANCE (PM) DECISION
1. List total breakdown repairs.
2. List idle production time.
3. List overhead and any equipment damage resulting
from the breakdown
Then calculate the net savings due to pm programs:
Pm=
TROUBLESHOOTING
Is described as a logical system of investigation designed
to yield the correct cause of breakdown in the shortest
possible time and with the least likelihood of error.
factors can indicate the machine breakdown
1. Performance.
2. downtime.
3. service life.
4. efficiency.
5. safety.
6. environmental impact.
7. cost.

10. The basic approach of Troubleshooting
1. Knowledge.
2. Logic.
3. Experience.
Data aids to troubleshooting
1. Background data sources.
2. Operational data sources.
3. Communication.
4. Systematic diagnosis.
SYMPTOM Overheating
FAULT Worn bearing
CAUSE Poor lubrication