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1. OPRM530: Reliability and Maintenance
Unit 3
Dr. Anuj Dixit
UID :29799

2. Maintenance concepts and strategies
 Maintenance is a critical aspect of ensuring the
reliable and efficient operation of systems,
equipment, and infrastructure.
 There are various maintenance concepts and
strategies aimed at preserving and optimizing the
performance of assets.

3. Preventive Maintenance (PM)
 Definition: Scheduled maintenance activities performed to
prevent equipment failure or degradation.
 Strategy: Regular inspections, lubrication, adjustments, and
component replacements at predetermined intervals.

4. Corrective Maintenance
 Definition: Unplanned maintenance performed to
restore equipment to a satisfactory condition after a
failure.
 Strategy: Reactive response to unexpected
breakdowns or malfunctions.

5. Predictive Maintenance (PdM)
 Definition: Maintenance activities based on the
monitoring of equipment condition and predicting
when maintenance should be performed.
 Strategy: Uses technologies like sensors and data
analysis to predict equipment failures and schedule
maintenance just in time.

6. Reliability-Centered Maintenance (RCM)
 Definition: A systematic approach to determine the
most effective maintenance approach for optimizing
reliability, safety, and cost.
 Strategy: Identifies critical components, failure
modes, and selects maintenance tasks based on risk
and impact.

7. Total Productive Maintenance (TPM)
 Definition: A holistic approach that involves everyone
in an organization to improve the effectiveness of
equipment.
 Strategy: Involves operators in maintenance tasks,
emphasizes proactive and preventive maintenance,
and aims at achieving zero breakdowns, zero defects,
and zero accidents.

8. Condition-Based Maintenance (CBM)
 Definition: Maintenance performed when the actual
condition of equipment or its components indicates
that it is necessary.
 Strategy: Monitors parameters such as vibration,
temperature, and oil quality to make maintenance
decisions.

9. Run to Failure (RTF)
 Definition: Allows equipment to operate until it fails,
and then maintenance is performed to restore
functionality.
 Strategy: Typically used for non-critical equipment
where the cost of preventive maintenance outweighs
the cost of occasional repairs.

10. Proactive Maintenance
 Definition: Maintenance activities that focus on
identifying and addressing potential issues before
they lead to failures.
 Strategy: Includes tasks such as root cause analysis,
reliability engineering, and continuous improvement.

11. Risk-Based Maintenance (RBM)
 Definition: Maintenance decisions based on the
assessment of risks associated with equipment failure.
 Strategy: Prioritizes maintenance tasks according to the
level of risk and potential consequences.

12. Asset Management
 Definition: The systematic coordination of activities related to an
organization's assets throughout their lifecycle.
 Strategy: Involves optimizing the performance, risk, and cost of assets
through effective planning, acquisition, operation, maintenance, and
disposal.

13. Design-out maintenance
 Refers to a proactive approach in which maintenance
requirements and challenges are considered and addressed
during the initial design phase of a system, equipment, or
facility.
 The goal is to minimize or eliminate the need for certain
types of maintenance by designing products and systems that
are inherently reliable, durable, and easy to maintain.
 This approach is part of the broader concept of "reliability
engineering" and contributes to achieving higher levels of
overall system reliability and availability.

14. Scheduled Maintenance
 Scheduled maintenance refers to routine and planned
maintenance activities performed at predetermined intervals or
based on specific criteria.
 The primary purpose is to prevent the occurrence of failures or
degradation of equipment over time.

15. Characteristics of Scheduled
Maintenance
 Preventive in Nature: Scheduled maintenance is typically preventive,
addressing known issues or potential failure modes before they cause
disruptions.
 Regular Intervals: Maintenance tasks are performed at regular intervals, such
as daily, weekly, monthly, or annually, depending on the type of equipment and
the nature of the operation.
 Predictable Downtime: Since scheduled maintenance is planned in advance,
the downtime associated with maintenance activities is predictable and can be
scheduled during periods of low demand or production.
 Examples: Lubrication, inspections, filter replacements, calibration, and other
routine tasks fall under scheduled maintenance.

16. Shutdown Maintenance
 Shutdown maintenance, also known as turnaround
maintenance or outage maintenance, involves the
complete or partial shutdown of a facility or a section
of a facility to carry out extensive maintenance,
repairs, or upgrades.

17.  Comprehensive Scope: Shutdown maintenance encompasses a wide
range of maintenance activities, including preventive, corrective, and
capital projects. It often involves overhauls, major repairs, and
equipment replacements.
 Extended Duration: Shutdowns are longer in duration compared to
scheduled maintenance intervals. They can last for days or weeks,
depending on the complexity of the maintenance work.
 Disruption to Operations: During a shutdown, the affected equipment
or facility is not operational, leading to a temporary halt in
production or services.
 Strategic Planning: The timing of shutdowns is often strategically
planned to coincide with periods of lower demand or when it is most
cost-effective to interrupt operations.
 Examples: Overhauls of industrial equipment, replacement of major
components, facility upgrades, and large-scale maintenance projects
are common during shutdown maintenance.
Characteristics of Shutdown Maintenance

33. Maintenance planning and scheduling are crucial
elements of effective maintenance management. These
activities help organizations optimize their resources,
minimize downtime, and ensure that maintenance
tasks are carried out efficiently.

34. Maintenance Planning:
Definition: Maintenance planning involves the identification of
maintenance activities, resources required, and the development of a
strategy to accomplish maintenance tasks.
Objectives:
1. Define maintenance tasks and activities.
2. Identify necessary resources (materials, labor, equipment).
3. Determine the sequence of tasks.
4. Develop a timeline for maintenance activities

35. Maintenance Scheduling:
Definition: Maintenance scheduling is the process of assigning specific
time slots or dates for the execution of planned maintenance activities.
Objectives:
Allocate resources efficiently.
Minimize downtime and disruptions.
Ensure that maintenance tasks are completed on time

36. Key Steps in Maintenance Planning and
Scheduling:
Job Identification and Definition:
Clearly define the maintenance task or job to be performed.
Identify the scope, objectives, and required resources.
Resource Identification:
Determine the materials, tools, equipment, and manpower needed.
Ensure availability of resources when scheduled.
Task Sequencing:
Establish the logical sequence of tasks to optimize efficiency.
Consider dependencies between tasks.
Estimation of Time and Duration:
Estimate the time required for each task.
Determine the overall duration of the maintenance job.

37. Key Steps in Maintenance Planning and
Scheduling:
Scheduling:
Assign specific dates or time slots for each task.
Consider factors such as equipment availability, production schedules, and personnel availability.
Communication:
Communicate the maintenance schedule to all relevant parties.
Ensure that everyone involved is aware of their roles and responsibilities.
Documentation:
Maintain detailed documentation of the maintenance plan and schedule.
Include information on resources, timelines, and any changes made during execution.