What is Maintenance?

&
Why Maintenance?
 Maintenance
Maintenance is work that is carried out to preserve an asset (such as a
roof or a heating boiler), in order to enable its continued use and
function, above a minimum acceptable level of performance, over its
design service life, without unforeseen renewal or major repair
activities
 Reasons for Maintenance
Maintenance serves to protect the owners’ real estate investment in a number of ways
 Physical Integrity
To keep the assets in good working order so as to minimize disruptions and downtimes.
 Risk Management
To keep the assets in a state of good repair for the owners’ health and safety.
 Aesthetic Preservation
To keep the assets from deteriorating in appearance and becoming unsightly.
 Responsible Stewardship
To ensure that the assets achieve their full potential service life.
 Duty of Care
To satisfy a legislated duty that is owed to owners, occupants and guest on the property.

 Duty to Mitigate
To prevent unnecessary damage to assets that may result in their premature failure.
 Types Of Maintenance
 Breakdown maintenance
 Preventive maintenance
1. Periodic maintenance ( Time based maintenance - TBM)
2. Predictive maintenance
I. Condition Monitoring
 Corrective maintenance
 Break Down
Maintenance
It means that people waits until equipment fails and repair it. Such a thing could be used when
the equipment failure does not significantly affect the operation or production or generate any
significant loss other than repair cost.

 Preventive maintenance
It is a daily maintenance ( cleaning, inspection, oiling and re-tightening ), design to retain the
healthy condition of equipment and prevent failure through the prevention of deterioration,
periodic inspection or equipment condition diagnosis, to measure deterioration. It is further
divided into periodic maintenance and predictive maintenance. Just like human life is
extended by preventive medicine, the equipment service life can be prolonged by doing
preventive maintenance.
 Periodic
maintenance
Time based maintenance consists of periodically inspecting, servicing and cleaning equipment
and replacing parts to prevent sudden failure and process problems

 Predictive maintenance
This is a method in which the service life of important part is predicted based on inspection or
diagnosis, in order to use the parts to the limit of their service life. Compared to periodic
maintenance, predictive maintenance is condition based maintenance. It manages trend values,
by measuring and analysing data about deterioration.
 Condition
Monitoring
Condition monitoring is the process of determining the condition of machinery while
in operation.
 The key to a successful condition monitoring programme includes:
1. Knowing what to listen for
2. How to interpret it
3. When to put this knowledge to use
 Successfully using this programme enables the repair of problem components prior
to
failure.
 Condition monitoring not only helps plant personnel reduce the possibility of catastrophic
failure, but also allows them to order parts in advance, schedule manpower, and plan
other repairs during the downtime.
 Corrective
maintenance
It improves equipment and its components so that preventive maintenance can be carried out
reliably. Equipment with design weakness must be redesigned to improve reliability or
improving maintainability
Advantages And Disadvantages
Break Down Maintenance
Advantages Disadvantages

Lower start up cost Unpredictability

Limited personnel requirement Equipment not maximised

Reduced maintenance costs Indirect costs

Potentially increased margins

 Preventive Maintenance
Advantages
Over all very cost effective
Flexibility can allow for adjustment of
schedule to accommodate other work
Increased equipment life
Saved energy cost resulting from
equipment running from pick efficiency
Reduced equipment or process failure
Over all saving between 12% to 18%
Disadvantages
Catastrophic failure still a risk
Labour Intensive
Performance of maintenance based on
schedule not required
Risk of damage when conducting
unneeded maintenance
Saving not readily visible without a
base line
 Predictive Maintenance

Advantages
Increased component operational
life/availability
Allows for pre-emptive corrective action
Decreased part and labour cost
Improved safety and environment
Energy savings
Over all saving between 8% to 12% over
preventive maintenance
Disadvantages
Increased investment of diagnostic
equipment
Increased staff training for analysing data
Saving not readily visible without
a baseline/history
 Condition Monitoring
Advantages
Extend bearing service life
Maximise machine productivity
Minimise unscheduled downtime
Safely extend overhaul intervals
Improve repair time
Increased machine life
Improve product quality
Reduce product cost
Enhance product safety
Disadvantages
Monitoring equipment costs
Operational costs (running the program)
Skilled personnel needed
Strong management commitment
needed.
A significant run-in time to collect
machine histories and trends is usually
needed.
 Corrective Maintenance

Advantages Disadvantages
Lower short-term costs Increased long-term costs due to
unplanned equipment downtime.
Requires less staff since less work is Possible secondary equipment or process
being done damage.
Prone to neglect of assets