UNIT-2

TYPES OF MAINTENANCE AND MAINTENANCE

STRATEGIES
 SYLLABUS

• Breakdown maintenance
• Planned maintenance
• Strategies
• Preventive maintenance
• Design out maintenance
• Planned lubrication
• Total productive maintenance
• Zero break down maintenance
• Preventive inspection of equipments.
 NAMES & ROLL N0.

• Sudhanshu Topwal (leader) (160970104054)

• Kirti Parihar(leader) (160970104023)
• Bhaskhar singh bhandari (160970104012)
• Jitendra pal jatav (160970104020)
• Mahesh bijalwan (160970104026)
• Praful rawat (160970104033)
• Rishabh chauhan (160970104041)
• Sanjay basera (160970104045)
• Shubham gusain (160970104048)
• Aqchat verma (670970104003)
• Pavan pundir (670970104008)
• vikash singh jaayara (670970104013)
 BREAKDOWN MAINTENANCE

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 unplanned.
 Examples of breakdown maintenance

• An example of planned breakdown maintenance is run-to-failure maintenance, where an organization has decided
that letting a piece of equipment break down before servicing is the most cost-effective and least disruptive option.
• Examples of unplanned breakdown maintenance include corrective maintenance and reactive maintenance.
Corrective maintenance is performed when a breakdown occurs between scheduled preventive maintenance
occurrences. Reactive maintenance is performed if a breakdown occurs because a maintenance strategy has not
yet been put in place.
 Advantages and disadvantage of breakdown maintenance
Advantage
Using breakdown maintenance when it makes sense can
help organizations focus on optimizing PM programs for
critical equipment.
Disadvantage
Unplanned breakdown maintenance can be more costly
than preventive maintenance, because it typically causes
downtime and interrupts production. It can also be
difficult to find the root cause of a breakdown when no
maintenance strategy is in place. Finally, breakdown
maintenance can raise health and safety issues if
technicians are rushing to fix a problem and taking risks
to do so.
 The bottom line: Breakdown maintenance can be a good
thing—when it’s planned

Though the term “breakdown maintenance” sounds catastrophic, if it’s part of a planned maintenance strategy, it can
often make a lot of sense for certain pieces of machinery. When breakdown maintenance is unplanned, though, it can
lead to costly downtime, health and safety risks, and halted production.
 PLANNED MAINTENANCE

Planned maintenance refers to any maintenance activity that is planned, documented, and scheduled.
The aim of planned maintenance is to reduce downtime by having all necessary resources on hand,
such as labour and parts, and a strategy to use these resources.

Types of planned Maintenance

There are two main types of planned maintenance.
• Planned preventive maintenance
• Planned and unscheduled maintenance
 Planned Preventive Maintenance

The first is planned preventive system , which is scheduled maintenance aimed at repairing
assets before they fail. An example would be conducting maintenance on a forklift after every
150 hours of operation.
Scheduled maintenance activities are tasks that are set up to occur ahead of time. They are
done so assets can remain functional for as long as possible without any unplanned downtime.
Scheduled maintenance is determined by Maintenance triggers, including time, usage, event,
and condition.
 PLANNED AND UNSCHEDULED
MAINTENANCE

The planned and unscheduled maintenance, which is based on having a strategy in place to repair or
replace an asset as quickly as possible when it fails. An example would be planning to have a sufficient
number of easily accessible power drills on hand so replacing a broken one is quick and easy for a
technician.
• Also known as run-to-failure maintenance, planned but unscheduled maintenance occurs in
situations where the maintenance plan for an asset is to wait for it to break.
• This approach is typically reserved for assets that have little or no impact on production. Tools,
such as power drills and measuring instruments, are a good example. It’s wasteful to premptively
replace these tools, as they inexpensive and are not critical to production. Instead, organizations
keep extra tools on hand so they are available when one fails.
• This is still considered planned maintenance (rather than reactive) because the assets are tracked
and a strategy to repair them is in place when they wear out, instead of being caught off guard by
failure.
 How to implement planned maintenance

There is no one-size-fits-all approach to implementing planned maintenance. Every facility is different

and requires a slightly different approach. However, there are few basic steps maintenance teams can
take to build a foundation for planned maintenance success.
Using planned maintenance software
Technology is an important ingredient for implementing planned maintenance. Leveraging planned
maintenance software, such as a CMMS, allows you to organize all the resources necessary to plan
maintenance, like labour and parts. Planned maintenance software makes it easy to handle schedules,
inventory, work orders and reports. This ensure triggers are set up properly, technicians can respond to
work quickly, and the right parts are always in stock so maintenance can be completed with little
disruption.
Organizing your assets
The first step is to take a survey of your assets and figure out which ones fit into each category of
planned maintenance. Remember, there is planned preventive maintenance and planned unscheduled
maintenance. Conducting a critically analysis can help you determine which assets require the most
attention and which ones lend themselves to a preventive approach.

Training and executing the strategy

Planned maintenance requires the entire team to participate and be aware of their responsibilities. It’s
crucial to ensure everyone is trained on new technology, processes and procedures. When everyone
knows exactly how they fit into a planned maintenance strategy and the resources available to them, it
makes implementation much smoother and more effective. If planned maintenance is completely new
for your team, consider testing the strategy to help them adjust to a new way of doing things.
 The impact of planned maintenance

Planned maintenance is a useful tool for making your maintenance operation more efficient. It
guarantees you have the right strategy and resources in place to tackle any kind of maintenance
quickly and easily, whether it’s scheduled or not. Implementing planned maintenance will be
different for every facility, but some tried and true ways to be successful include organizing your
assets, using planned maintenance software, training and executing properly and building
planned maintenance checklists. With these tools and methods, your team will spend less time
putting out fires and more time looking for opportunities to improve
 MAINTENANCE STRATEGIES

STRATEGY

•WHAT ?

•The art of planning and directing resources for their most efficient and effective use.

WHY?
• Work in a systematic way .

• Continuous flow of work.

• Reduce time.
 Types of strategies

• Corrective Maintenance
• Preventive Maintenance
• Risk-based Maintenance
• Condition-based Maintenance
 Corrective Maintenance

• it is simply represent the option where a corrective action taken to remove the fault or repair to failure.
 PREVENTIVE MAINTENANCE
(INTERVAL BASED)

• Preventive maintenance (PM) uses regularly scheduled inspections, tests, services, repairs, replacements, and
other tasks to reduce the frequency and impact of equipment failures.
• These maintenance activities are performed on a calendar or operating time interval basis to extend the life of
equipment and prevent premature failure.
 Risk-based Maintenance

Risk-Based Maintenance is used as a strategy when the likelihood of an asset’s failure may have severe
consequences. In other words, assets that carry a high risk need priority when it comes to maintenance
 Condition-based Maintenance

Condition-based maintenance (CBM) is a maintenance strategy that monitors the actual condition of an asset to
decide what maintenance needs to be done. CBM dictates that maintenance should only be performed when certain
indicators show signs of decreasing performance or upcoming failure.
 PREVENTIVE MAINTENANCE
• Preventive maintenance is maintenance that is regularly performed on a piece of equipment to lessen
the likelihood of it failing. It is performed while the equipment is still working so that it does not break
down unexpectedly. In terms of the complexity of this maintenance strategy, it fall between run to
failure or predictive maintenance.
• Preventive maintenance is the systematic maintenance and servicing of machines and facilities so as
to provide satisfactory operating conditions. It is achieved through methodical inspection, and finding
and correcting developing failures before they actually happen.
• Preventive maintenance is performed on a schedule, which detects and lessens the degradation of
components and systems. Preventative maintenance has the aim of increasing reliability, saving costs
from major failure or down time, reducing the risk of failure and extending the life of machine or
facilities.. Preventive maintenance cannot assure escape from catastrophic failures and sometimes
may seem to be unnecessary.
• Preventative maintenance includes test operations as per design, diagnosis, replacing worn out parts,
measurements, lubricating, tightening and adjustments.
 WHY PREVENTIVE MAINTENANCE

1. Save Money

2. Maximize Efficiency

3. Prolong Equipment Life

.
4. Reduce Maintenance Costs

5. Improve Safety and Reliability

 TYPES OF PREVENTIVE MAINTENANCE

Preventive maintenance can be scheduled on a time or usage based TRIGGER.

Let’s look at an example for each.
• Time-based preventive maintenance
A typical example of a time-based preventive maintenance trigger is a regular inspection on a critical piece of
equipment that would severely impact production in the event of a breakdown.
• Usage-based preventive maintenance
Usage-based triggers fire after a certain amount of kilometres , hours, or production cycles. An example of this
trigger is a motor-vehicle which might be scheduled for service every 10,000km.
 ADVANTAGES

• Less risk factor- Because the equipment and your building are being regularly checked, they are at
less risk to breaking down without notice. Therefore creating a safer working environment for
employees.
• Follows a schedule- By following a schedule, you are able to keep to a budget while maintaining your
building. Also you will be able to keep track of all your equipment and pin point times when you will
need to replace your equipment.
• Longer equipment/building life- When equipment is being checked and maintained, it will be kept in its
best shape, therefore extending its lifetime. With routine check-ups on building parts such as pipes,
boilers, and roofing you’ll extend the life of your building as well.
• Money saving-Over time, you will see that less money is being spend because you will not have to
replace equipment as much, as well as dealing with last minute break downs. While there still may be
some unplanned maintenance needed, the likely hood will go down when the building and equipment
are regularly checked.
 DISADVANTAGES

• More money upfront- When initially starting a preventative maintenance plan, it will cost you more to regularly
maintain equipment and the building, than it would be if you waited for things to simply break down.
• Over maintenance- Because there is a regular plan, sometimes items may not need to be checked as often as
planned. If this is the case, you can change your maintenance plan to checking the specific equipment or areas
less often, while still maintaining a schedule.
• More workers- Preventative maintenance require more workers because regular checks are a must. When
compared to reactive maintenance, you simply need to call someone in for a onetime fix. Instead this method
requires workers to always be on site and perform daily works.
 DESIGN OUT MAINTENANCE

Content
• Design out maintenance
• Major tenets of design-out maintenance
• Conclusion
 DESIGN OUT MAINTENANCE

If the maintenance cost or downtime cost of equipment is high, then the Design Out Maintenance strategy can often be
effective. This strategy differs from all the others in that it is a one-off activity, as opposed to a repetitive activity
designed to prevent failure. Design Out Maintenance aims to redesign those parts of the equipment which consume
high levels of maintenance effort or spares cost or which have unacceptably high failure rates.
• The high maintenance costs may have been caused by a number of factors, including:
• Poor maintenance
• Operation of equipment outside of its original design specification
• A poor initial design
The Design Out Maintenance strategy can only be implemented effectively if high maintenance cost items can be
identified and the reasons for the high cost understood. It is often the best strategy to take when breakdowns are too
frequent or repair is too costly.
 MAJOR TENETS OF DESIGN-OUT
MAINTENANCE

Processes such as the Management of Change have been adopted to cater for the likes of
asset design alterations under the auspices of Improvement Maintenance, and this
essentially calls for the process of design changes to the asset to eliminate reliability issues
previously encountered, hence Improvement Maintenance is essentially designout
maintenance. Design-out maintenance is a strategy that aims for improvement rather than
just conducting maintenance activities to ensure system functionality, and its focus is the
improvement of system design to reduce the maintenance burden or even eliminating
maintenance altogether.
Design-out Maintenance depicted as an Improvement Strategy
Design-Out maintenance in conjunction with conventional maintenance strategies
 PLANNED 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.
 TYPES OF LUBRICATION PROCESS

1. SPLASH LUBRICATION-: Single passing of lubricant through the friction area , e.g. splash lubrication for
transmission.

2. CIRCULATING LUBRICATION-: All lubrication points must be tight without leakages, lubricant is forced to flow
continuously through lubrication points.
 TYPES OF LUBRICATING OIL

1. MINERAL OILS-: Mineral oils are basically hydrocarbons often with same additives introduce specific
characteristic feature in the oil.

2. SYNTHETIC OILS-: Synthetic oils are produced under controlled conditions industrially from chemical base and
additives. These are pure, idealized lubricants whose molecules are uniform in weight and shape.
 TYPES OF LUBRICATION

• Full-film lubrication can be broken down into two forms: hydrodynamic and elastohydrodynamic.

• Boundary lubrication is found where there are frequent starts and stops, and where shock-loading conditions are
present.

• Mixed lubrication is a cross between boundary and hydrodynamic lubrication.

“ADVANTAGES”
 TOTAL PRODUCTIVE MAINTENANCE (TPM)

• What is tpm • What is tpm

TPM Is total productive maintenance. It is a concept of
• Goal of tpm maintaining equipment and plant as well as improve the
• Why tpm is required quality of product.

• target of tpm It is also known as the medical science of machine.

It helps to improve machine not to go in breakdown.
• What are the pillars of tpm
 TPM

Goal of tpm Requirement Target of tpm

The goal of tpm is to increase To produce the product in The following points on which
the production rate. less time,less cost and we will measure the target of
without any loss. tpm:-
To produce the product SAFETY-Target under tpm is
Another goal of tpm is :-
without effecting the quality of zero accident.
Zero failure product. QUALITY-Product to be
Zero accident produced as defect free.
Zero defect COST-To produce the
Zero loss product at minimum cost.
 Pillars of TPM

It has 8 points for implimenting it at working place.these 8 points are called 8 pillars of tpm .
1. Jishu Hozen (Autonomous maintenance)
2. Kobestsu Kaizen (Focused maintenance)
3. Planned maintenance
4. Education and training
5. Early equipment and development of management
6. Administration and support function management
7. Safety,health and environment management
8. Quality management
 ZERO BREAK DOWN

• Identify accelerated deterioration factors and carry out restoration and improvement of equipment condition.
• Extend inherent service life of the equipment.
• Research the natural deterioration pattern.
• Search of deterioration parameter.
• Implement predictive maintenance.
 APPROACH TO ZERO BREAKDOWN

Successful zero breakdown maintenance is built on the following hall mark fundamentals :
• Zero breakdown equipment needs quality design, low stress and less fatigued parts kept in good health
• To stop human error from causing plant and equipment failures needs a team of talented top persons getting
involved right from indenting, procurement , selection & design stage.
• Organizations need to redefine what businesses they are in and want to be in, reevaluate processes, rationalize
systems, benchmark and measure,and create new sources of revenue .
 DO’S

• Assign specific responsibility to each team member .

• Introduce cross functional work group .
• Implementation plan with time and target .
• Monitor project by project activity.
 DONT’S

Why it was not done in the past ?

Who gets the credit ?

Previous trial failed !

Preventive inspection of equipment
 PURPOSE OF INSPECTION

To identify whether work equipment can be operated, adjusted and maintained safely – with
any deterioration detected and remedied before it results in a health and safety risk.
 What should the inspection cover?

• An inspection can vary in its extent, as the following demonstrate:

 quick checks before use (eg electric cable condition on hand-held power tools,
functional testing of brakes, lights on mobile machinery)

 weekly checks (eg presence of guarding, function of safety devices, tyre pressures,
and the condition of windows, mirrors and CCTV on mobile plant)

 more extensive examinations, undertaken every few months or longer (eg general
condition of a ladder, close examination of a safety harness, portable appliance
testing).
When should work equipment that needs inspection be
re-inspected?
• Work equipment which is exposed to conditions causing deterioration that could
result in a dangerous situation should be inspected at suitable intervals, and after
every event liable to jeopardise its safety.
• The frequency of inspection may vary, depending on environmental conditions (eg
than if used in an indoor environment).
• The frequency of inspection should be determined through risk assessment, taking
account of the manufacturer's recommendations, industry advice and your own
experience.
• equipment subject to harsh outdoor conditions is likely to need more frequent
inspections
 Who should carry out the inspection of work
equipment?

Equipment can be inspected by anyone who has sufficient knowledge and experience of it to
enable them to know:
• what to look at
• what to look for
• what to do if they find a problem,
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